The present invention relates to an apparatus for accurately positioning and supporting modular tooling, and more particularly, an apparatus that provides a wide range of fine adjustment and rigid support for modular tooling to ensure accurate geometric positioning of a workpiece during machining and/or assembling of the workpiece.
The assembling and/or welding of various workpieces is often a challenging task in the manufacturing industry. For example, in the automotive industry, sheet metal stampings must often be welded together in order to create a single assembled or preassembled part. Prior to welding the sheet metal stampings, the stampings must be positioned in a highly accurate and repetitive geometric position in order that the sheet metal stampings may be accurately welded into an assembled position. Failure to do so may lead to the improper sizing and positioning of the assembled workpiece relative to the remaining parts of the automobile. The positioning of the sheet metal stampings prior to welding is often referred to as the geometric positioning of the workpiece.
In order to maintain the geometric positioning of the workpiece, previous designs have utilized heavy, rigid, structural members that are supported and moved by manipulators, such as robotic arms. These structural members are typically fabricated from heavy-duty steel so as to ensure the integrity and positioning of the end effector tooling that is mounted thereon. Such end effector tooling may include various power clamps, power grippers, and/or pin locators to locate and secure the workpiece in a predetermined geometric position. The adjustability and/or flexibility of the positioning and movement of the end effector tooling has been limited in such previous designs, as the previous designs typically concentrate on the rigidity and accuracy of the end effector tooling. This is to ensure that if the end effector tooling were to come into contact with something other than the workpiece, the end effector tooling will not be compromised, but rather, the end effector tooling will maintain the geometric positioning necessary to weld and assemble accurate workpieces.
The disadvantage to such previous designs is that they are typically heavy and non-flexible in design. Thus, the manipulator or robotic arm must be large and powerful enough to support and move such heavy tooling. In addition, the lack of flexibility does not allow for a high degree of adjustability to the end effector tooling such that the end effector tooling may be adjusted for a variety of different workpieces. The inability of such designs to adapt to various workpiece designs requires that the end effector tooling be dedicated to the specific configuration of one particular workpiece. This requires that a multitude of tooling be purchased and provided thereby creating an undesirable inefficiency in the industry.
It would be desirable to provide lightweight, flexible tooling that provided for the accurate positioning and support of end effector tooling to ensure the geometric positioning of a variety of workpieces during the machining and/or assembling of the workpiece.
The invention provides an apparatus for accurately positioning, adjusting, and supporting end effector tooling to ensure proper geometric positioning of a workpiece during the machining and/or assembling of the workpiece. The tooling apparatus includes an elongated, substantially cylindrical backbone that is connectable to a manipulator. At least one saddle mount is connected to the backbone, and at least one primary arm mount is connected to the saddle mount. At least one substantially cylindrical primary arm is connected to the primary arm mount, and at least one tooling mount is connected to the primary arm and is connectable to the end effector tooling.
The saddle mount may have a substantially U-shaped configuration that includes a cap that is connected to the open end of the U-shaped configuration to close the open end of the U-shaped configuration. The saddle mount may also include at least one mounting surface for attaching the arm mount thereto. The U-shaped configuration and the cap cooperate to form a throughbore to receive and secure the backbone to the saddle mount. A dowel pin is connected to the saddle mount and extends into the throughbore to engage an aperture in the backbone for properly locating and securing the backbone with respect to the saddle mount. Furthermore, the cap of the saddle mount may include a plurality of threaded apertures adaptable to mount tooling hardware to the cap.
The apparatus may include a breakaway arm mount that is connected to the primary arm. The breakaway arm mount includes a weakened section that breaks upon realizing an impact to the primary arm that is greater than a predetermined level of force. The apparatus may further include a lock ring for connecting the primary arm to the saddle mount, wherein the lock ring provides radial and axial adjustment of the primary arm. The lock ring may include a pair of substantially similar semi-cylindrical discs that are connected together to form a bore extending therethrough for receiving the primary arm. Also, a locating pin may extend through the pair of semi-cylindrical discs and through a pair of apertures in the primary arm for properly locating and securing the primary arm to the pair of semi-cylindrical discs, wherein the locating pin has a longitudinal axis substantially perpendicular to the longitudinal axis of the primary arm. Additionally, the semi-cylindrical discs may include threaded apertures that extend substantially parallel to the longitudinal axis of the primary arm, wherein the threaded apertures allow the semi-cylindrical discs and the primary arm to be mounted in various rotational positions.
The apparatus may also include a transition mount that has a first substantially flat surface that is connected to the saddle mount and a second substantially flat surface that is connected to the primary arm mount, wherein the first surface and the second surface are disposed at acute angles with respect to one another.
A blade end mount may be provided having a pair of substantially similar semi-cylinders and a plate therebetween connected together to form a bore for receiving and securing the primary arm to the blade end mount. A dowel rod extends from the end mount into the bore and through an aperture provided in the primary arm for locating and securing the primary arm to the blade mount. Furthermore, the plate of the blade end mount may have a substantially flat mounting surface for mounting the end effector tooling substantially perpendicular to a longitudinal axis of the primary arm.
The apparatus may also include an end mount that has a pair of substantially similar semi-cylinders that are connected together to form a bore for receiving and securing the primary arm, wherein a dowel rod extends from the end mount into the bore and through an aperture that is provided in the primary arm for locating and securing the primary arm to the end mount. Furthermore, the end mount has a substantially planar surface that is connected to the pair of semi-cylinders and extends substantially perpendicular to the longitudinal axis of the primary arm for mounting the end effector tooling thereto. Furthermore, the substantially planar surface of the end mount may have a plurality of adjacent apertures linearly aligned, and a pair of slots extending therethrough.
The apparatus may further provide an accessory clamp that has a flexible band formed in a substantially U-shaped configuration, wherein the ends of the U-shaped configuration are connected to a bracket. Furthermore, the bracket may have threaded apertures that are connectable to tooling hardware. Additionally, a cable tray having a hollow, substantially rectangular configuration may be connected to the bracket.
The apparatus may also include a secondary arm mount. The secondary arm mount has a first throughbore for receiving the primary arm. A dowel pin extends from the secondary arm mount into the throughbore and through an aperture in the primary arm to properly position and secure the primary arm to the secondary arm mount. The secondary arm mount also has a second throughbore for receiving a secondary arm. A dowel pin extends from the secondary arm mount into the second throughbore and through an aperture in the secondary arm to properly position and secure the secondary arm to the secondary arm mount. Furthermore, the secondary arm mount has a substantially flat mounting surface that is connectable to the end effector tooling.
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout several views and wherein:
Referring to the drawings, the present invention will now be described in detail with reference to the disclosed embodiment.
The apparatus 10 includes a rigid support member or backbone member 14 that is connectable to a manipulator, such as a robotic arm (not shown). The backbone member 14 has a plurality of annular coupling or collar members 16 mounted thereon in predetermined longitudinally spaced positions. A mounting plate 18 may be connected to a pair of collar members 16 whereby the manipulator or robotic arm is connected via the mounting plate 18 to the backbone member 14. A plurality of support structures 20 are connected to at least one of the collar members 16 in predetermined positions. The support structures 20 support end effector tools 22, such as a power clamps, power grippers, and/or a locator pins. The apparatus 10 provides accurate positioning of the end effector tools 22 so as to accurately and repeatably position the workpieces 12 in a predetermined geometric position so that a particular machining or assembling operation, such as welding, may be performed on the workpieces 12. Such geometric positioning may hold tolerances up to + or ā0.25 mm
In order to provide the apparatus 10 with the appropriate rigidity and support, the backbone member 14 is fabricated from a substantially rectangular, hollow tubular structure having rounded corners thereon. The backbone member 14 is fabricated from a lightweight, high-strength rigid material, such as carbon fiber, steel, castings, aluminum, or other lightweight, high-strength, rigid materials. The backbone member 14 is fabricated in a high-precision manner such that the backbone member 14 may maintain a high degree of accuracy.
The collar members 16 are mounted on the outside surface of the backbone member 14. The collar members 16 are substantially rectangular and hollow so as to receive the backbone member 14. The collar members 16 are also fabricated from a lightweight, high-strength material, similar to that provided for the backbone member 14. The collar members 16 are fixedly secured to the backbone member 14 by bonding or welding. However, it is anticipated that other securing means may be utilized such as expanding the backbone member 14 onto the collar members 16 when the backbone member is fabricated from a carbon fiber material.
Following securement of the collar members 16 on the backbone member 14 in predetermined longitudinally spaced positions, six apertures, formed as two parallel rows, are machined in each of the four sides of each collar member and in the underlying backbone member for receiving dowel rods 33 and threaded fasteners 32 from the support structures 20. The central apertures 24a on each row on each side of the collar member 16, as well as the aligned central apertures 14a in backbone member 14, are unthreaded and receive a dowel rod 33, and the outboard apertures 24b in each row on each side of the collar member 36, as well as the aligned outboard apertures 14b in backbone member 14, are threaded for receiving threaded fasteners 32. Each of the four sides of the collar members 16 may also have a recessed portion 26 for reducing the amount of material and weight associated with the collar members 16. Again, the collar members 16 are fabricated in a high-precision manner so as to maintain a high degree of accuracy when mounting the end effector tooling 22 thereon.
Alternatively, and as seen in
Various support structures 20 may be utilized to connect the end effector tooling 22 to the collar members 16. In one support structure embodiment, seen in
The support structure 20 of the embodiment of
In an alternate embodiment of support structure 20, as seen in
In a further alternate embodiment of the support structure 20, seen at 64 in
The positioning apparatus of the invention further includes a plurality of boom rods 36. Each boom rod 36 is substantially rectangular and hollow and includes rounded corners. Each boom rod 36 is telescopically received at its inboard end in a socket column member 34, in a socket portion 35b of a unitary member 35, or in the āUā shaped socket portion 64b of a support structure 64, and may be fixedly secured to the member 34, socket portion 35b, or socket portion 64b by bonding or welding. Each boom rod 36 is also manufactured in a highly precise manner and fabricated from a light weight, high strength rigid material as previously described for the rigid support member 14.
As best seen in
Base member 42 includes a substantially rectangular tubular portion 42a for telescopically receiving the outboard end of a boom rod 36 and a base portion 42b which is integral with the tubular portion 42a. The base portion 42b provides a substantially flat mounting surface having contoured parallel grooves 42c formed therein. A pair of spaced substantially parallel slots 42d extend through the base portion 42b of the base member 42 at right angles to the grooves 42c.
Each adjustable mounting plate 43 is coupled to the base portion 42b of a base member 42. The adjustable mounting plate 43 has an L-shaped configuration including a webbed portion 58 extending integrally between a long leg portion 60 and a short leg portion 62. The short leg portion 62 has a contoured ribbed surface 64 formed on the bottom thereof for matingly engaging the grooves 42c on the base portion 42b of the base member 42 whereby to adjustably mount the mounting plate on the base member. A pair of apertures extend through the short leg portion 62 of the mounting plate 43 and align with the slots 42d in the base portion 42b of the base member 42. A pair of conventional fasteners 50 extend through the apertures in the leg portion 62 and through the slots 42d, and a nut 66 is provided on the threaded end of the fasteners 50 to tighten the mounting plate 43 on the base member 42 in any desired position of lateral adjustment. Indicia 68 are provided on an edge of the base portion 42b of the base member 42 so as to indicate the position of the adjustable mounting plate 43 relative to the base member. Each adjustable coupling 38 is manufactured in a highly precise manner and fabricated from similar materials as the rigid support member 14.
Each end effector tooling 22 is mounted on an adjustable mounting plate 43 utilizing apertures extending through the adjustable mounting plate which correspondingly align with apertures provided in the end effector tooling 22. Conventional fasteners extend through the apertures in the adjustable mounting plate 43 and into the apertures provided in the end effector tooling 28 to secure the end effector tooling 22 to the adjustable mounting plate 43. As previously noted, various end effector tooling 22 may be utilized, such as power grippers, power clamps, locator pins, etc.
In operation, the apparatus 10 is typically set up prior to connecting the apparatus 10 to a manipulator or a robotic arm. The end effector tooling 22 is adjusted with respect to the apparatus 10 so as to provide proper geometric positioning of the workpiece 12. The end effector tooling 22 may be adjusted by moving and/or adjusting the collar members 16 with respect to the backbone member 14 and by adjusting support structures 20 with respect to collar members 16. The length of the boom rods 36 may also be adjusted to provide further adjustment to the end effector tooling 22. The adjustable mounting plate 43 also provides varied adjustment of the end effector tooling 22. Further, as seen at 70 in
In an additional embodiment, an apparatus 100 for accurately positioning and supporting a workpiece 12, such as stamped sheet metal parts, in a predetermined geometric position so that certain machining and assembling operations may be performed on the workpiece 12, as shown in
The apparatus 100 includes a rigid, elongated, substantially cylindrical support member or backbone member 102. The backbone 102 may have at least one saddle mount 104 connected to the backbone in predetermined longitudinally-spaced positions. Either the backbone 102 or a portion of the saddle mounts 104 may be connectable to a manipulator, such as a robotic arm (not shown). A mounting plate 106 may be connected to the saddle mounts 104, whereby the manipulator or robotic arm is connected via the mounting plate 106 to the backbone member 102. The mounting plate 106 may have a fixture 108 mounted thereon for allowing for easy engagement with the manipulator or robotic arm. At least one primary arm mount 110 may be connected to at least one of the saddle mounts 104. Each primary arm mount 110 may include a breakaway arm mount 112, which will be described in further detail later in the specification, and the primary arm mount 110 may also include a lock ring 114, as will also be described in further detail later in the specification. A substantially cylindrical and rigid primary arm 116 may extend from the primary arm mount 110, wherein a tooling mount 118 may be connected to the primary arm 116. The tooling mount 118 may include a secondary arm mount 120, which connects to the primary arm 116 and is connected to a secondary arm 122, which is similar to the primary arm 116. The tooling mount 118 may also include a blade end mount 124, which may be connected to the primary arm 116 or the secondary arm 120 and further provides a mounting surface for mounting end effector tools 22. In addition, the tooling mount 118 may include an end mount 126, which may also be connected to the primary arm 116 or the secondary arm 120 while also providing a planar mounting surface for connecting the end effector tooling 22 thereto. Through the use of the above-noted apparatus, the end effector tooling 22 can accurately position and support a workpiece 12 for the appropriate machining and assembling of the workpiece 12.
In order to provide the apparatus 100 with the appropriate rigidity and support, the backbone member 102 is fabricated from an elongated, substantially cylindrical hollow structure. The backbone 102 may be fabricated from a lightweight, high-strength, rigid material, such as carbon fiber, steel, castings, aluminum, or other lightweight, high-strength, rigid materials. The backbone 102 is fabricated in a high-precision manner such that the backbone 102 may maintain a high degree of accuracy. The backbone 102 may have a plurality of apertures 103 extending therethrough for receiving dowel pins 128 from the saddle mounts 104 for properly locating and positioning the backbone 102 relative to the saddle mounts 104.
In order to secure the end effector tooling 22 to the backbone 102, the apparatus 100 provides the saddle mounts 104, as best seen in
In order to extend the end effector tooling 22 from the saddle mounts 104, the primary arm mount 110 may be connected to one of the flat mounting surfaces 136 on the saddle mount 104. The primary arm mount 110 may provide the breakaway arm mount 112, as seen in FIGS. 9 and 13-14. The breakaway arm mount 112 has a substantially rectangular base portion 146, which is connected to the flat mounting surface 136 of the saddle mount 104 through the use of four threaded fasteners and the dowel rods 142, which utilize to properly locate and position the breakaway arm mount to the saddle mounts 104. A substantially cylindrical portion 148 of the breakaway arm mount 112 is integrally connected to the base portion 146. A narrowed neck portion 150 is provided between the base 146 and the cylindrical portion 148 of the breakaway arm mount 112 to provide a weakened portion of the breakaway arm mount 112. The cylindrical portion 148 of the breakaway arm mount 112 receives the primary arm 116, and the primary arm 116 abuts a shoulder within the cylindrical portion 148 of the breakaway arm mount 112. Thus, when the primary arm 116 realizes a lateral force that is beyond a predetermined limit, the neck portion 150 of the breakaway arm mount 112 will break, thereby preventing any damage to the remaining tooling. Thus, by simply replacing the breakaway arm mount 112, the apparatus 100 can be easily replaced at a minimum cost and time. The breakaway arm mount 112 is fabricated in a high-precision manner so as to maintain a high degree of accuracy when mounting the end effector tooling 22 thereon. The breakaway arm mount 112 may be fabricated from aluminum alloy or other lightweight, high-strength material. The cylinder portion 148 of the breakaway arm mount 112 may have a plurality of threaded apertures and non-threaded apertures for receiving threaded fasteners and dowel pins on the face of the cylinder portion 148 of the breakaway arm mount 112.
In order to provide rotational and axial movement of the primary arm 116, the primary arm mount 116 may also provide the lock ring 114 connected to the breakaway arm mount 112, as best seen in
The primary arm 116 is also fabricated in a high-precision manner so as to maintain a high degree of accuracy when mounting the end effector tooling 22 thereon. The primary arm 116 is fabricated from a lightweight, high-strength steel, such as aluminum. The primary arm may have a plurality of apertures extending therethrough for receiving dowel pins in order to properly position the primary arm 116 with respect to the end effector tooling 22.
In order to connect the end effector tooling 22 to the primary arm 116, the tooling mount 118 may be connected to the primary arm 116. The tooling mount 118 may include the secondary arm mount 120, which has a substantially semi-circular portion 164 connected to the rectangular portion 162 of the secondary arm mount 120, as shown in
The tooling mount 118 may also provide the blade end mount 124 connected to the primary arm 116 or the secondary arm 122, as shown in
The tooling mount 118 may also include the end mount 126, as shown in
Various blade mounts 186 may be connected to the end mount 126. As seen in
The tooling mounts 118 may also provide a transition mount 194 for mounting the end effector tooling 22 at a particular angle. The transition mount 194, as seen in
In order to organize and guide any wires, cables, or hoses that may be utilized in the apparatus 100 or to attach junction boxes and other equipment to the apparatus 100, an accessory clamp 208 may be connected to the backbone 102 or the primary arm 116 or the secondary arm 122, as shown in
In operation, the apparatus 100 is typically set up prior to connecting the apparatus 100 to a manipulator or a robotic arm. The end effector 22 is adjusted with respect to the apparatus 100 so as to provide proper geometric positioning of the workpiece 12. End effector tooling 22 may be adjusted by moving and/or adjusting the various primary arm mounts 122, second arm mounts 120, and tooling mounts 118 with respect to the backbone 102 and the saddle mounts 104. The length of the primary and secondary arms 116, 122 may also be adjusted to provide further adjustment to the end effector tooling 22. Various combinations of the saddle mounts 104, primary and secondary arm mounts 110, 120, and tooling mounts 118 may be utilized to give varied positions of the end effector tooling.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments, but to the contrary, it is intended to cover various modifications or equivalent arrangements included within the spirit and scope of the appended claims. The scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is performed under the law.
The present application is a continuation-in-part of U.S. patent application Ser. No. 11/403,277, filed on Apr. 13, 2006, which claims priority to U.S. Provisional Patent Application No. 60/696,865, filed on Jul. 6, 2005.
Number | Date | Country | |
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60696865 | Jul 2005 | US |
Number | Date | Country | |
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Parent | 11403277 | Apr 2006 | US |
Child | 12105403 | US |