Patent Grant
11660658
This application is a U.S. National phase application of International Application No. PCT/GB2018/053524 filed Dec. 5, 2018, which claims priority to Application No. GB 1720275.5 filed Dec. 5, 2017, the entire contents of both of which are incorporated by reference herein.
The present application is being filed on the same date as applications titled “Nose Arrangements for Fastener Setting Machines, and Related Methods” (GB1720277.1) and “Fastener Handling Devices for Fastener Setting machines, and Related Methods” (GB1720248.2), the contents of which are fully incorporated herein by reference.
The present application relates to magazines for supplying fasteners such as rivets to a rivet setting tool. The present application also relates to systems for supplying rivets to a setting tool, the systems including one or more rivet magazines, and to related methods. In particular, the present application relates to magazines, systems and methods for supplying self-piercing rivets. More particularly, the present application relates to magazines, systems and methods of the type used for supplying rivets and/or self-piercing rivets to a setting tool having a nose arrangement and a punch for setting the rivets, the setting tool being mounted on a support such as a C-frame. The C-frame may be mounted on a movable arm, such as a robotic arm. These magazines store the fasteners in proximity of the setting tool, in readiness for any setting operations carried out by the setting tool. Although the focus of the present disclosure is on rivets (and, in particular, on self-piercing rivets), certain aspects are instead readily applicable to fasteners more generally, as it will be appreciated from the detailed description set out below.
Various systems and methods for setting fasteners such as rivets and self-piercing rivets are known which use a bulk-supply apparatus to supply the rivets to a setting tool. In some systems, the setting tool comprises a nose arrangement and a punch for setting the rivets. The setting tool is mounted on a support structure such as a C-frame. The C-frame can be mounted on a robotic arm so that a number of automatic operations can be carried out by the robot at the required locations.
The nose arrangement is generally disposed under the punch, and guides the punch and the rivets during a setting operation.
A die assembly is also usually provided on the support structure, opposite the nose arrangement, to react the force applied by the punch to the workpiece during a setting operation. In this way, the workpiece is sandwiched between the nose arrangement and the die assembly during a setting operation, and the punch is operated to set the rivet.
Systems of the type described herein typically feed the rivets to the nose arrangement through suitably profiled flexible delivery tubes. The rivets can thus be delivered to the setting tool by means of compressed air, and/or gravity.
The rivets are supplied singularly or in groups, and generally therefore require one or more rivet handling mechanisms along the supply lines so that only the required rivet or rivets are supplied when necessary. These mechanisms generally involve some form of mechanical interaction with the rivets, and this may happen at various stages along the path of the rivets from the bulk-supply apparatus to the setting tool.
The flexible delivery tubes may be connected to one or more magazines to locally store, closer to the setting tool, up to a predetermined number of rivets in readiness for installation. It is known to provide some sort of removable, replaceable magazines to simplify the supply operations. However, several problems are associated with the systems of the prior art.
The rivets, for example, are susceptible to jamming in the flexible delivery tubes due to ingress of dust or dirt, due to any portions of the flexible tubes presenting high curvature, or due to wear and tear of the tubes themselves. The flexible delivery tubes, for these very reasons, may require frequent replacement and this may cause unwanted downtime.
Further, the flexible delivery tubes may require a certain working envelope to operate flexibly, and this may necessitate special considerations about how to mount the setting tool on the robotic arm.
As a result, the systems of the prior art may operate not completely satisfactorily, and/or, at the very least, may lack the desired compactness.
It is therefore desirable to minimise, or do away with, the flexible delivery tubes.
It is also desirable to transfer the rivets with the least amount of disruption possible along the rivet supply lines.
It is also desirable to maintain the rivets on their path without dislocation.
It is also desirable to move the rivets seamlessly, so that they can, for example, be gently brought to a halt, and restarted, as and when necessary, along the rivet supply line.
If all the various communicating rivet-supply components in the rivet supply line are connected, and open to the transit of the rivets, it would be desirable to transfer the rivets to the nose arrangement in a continuous (ie uninterrupted), yet reliable, fashion.
There is accordingly also a desire to do away with any potential catch points for the rivets, especially in the above mentioned ‘open’ conditions.
When the rivets are supplied from the bulk-supply apparatus to the magazine, they typically pass through a docking interface that allows the magazine to be refilled when empty. The magazine may thus require a gate to open during the docking and/or loading operation, and close when full, to prevent any rivets from falling out, and to seal the magazine end, so that a compressed air source can then be coupled to the magazine to provide a rivet motive force, when required. Such gates are complex, particularly when the system is designed to operate under the motive force of compressed air, and may add considerable cycle time, and cost, to the operations.
It is also desirable to provide an improved design of magazine which does away with, or that at least reduces, any sealing requirements and/or which may work equally adequately under pressure or suction, or at atmospheric pressure.
There is accordingly also a desire to provide a rivet supply line, or at least a portion thereof, that can be effortlessly, or at least advantageously, sealed against air leakage and/or dust ingress.
After the rivets have completed their path through the rivet supply system, a rivet transfer system is typically provided to transfer the rivets to a stand-by position under the punch, in readiness for the setting operations. The transfer system may involve direct transfer by gravity, air propulsion, a mechanical pusher or probe and/or a dedicated transfer mechanism that traps and senses the rivets presence. Such a dynamic delivery of the rivets from the rivet supply system to the stand-by position is generally problematic in terms of rivet stability, dust ingress and sensing, and typically requires a number of moving mechanical parts that may also suffer wear and tear. This is undesirable, as it may lead to faults or can constitute another source of downtime.
It is therefore also desirable to improve the rapidity, efficiency and/or reliability of the transfer of the fasteners to the stand-by position, under the punch, in readiness for installation.
Known rivet supply systems and methods have only limited capabilities to handle different types of rivets and/or different sizes thereof.
It is thus also desirable to provide magazines, rivet delivery systems and methods which can simultaneously or interchangeably handle a variety of rivet types and/or sizes to provide maximised flexibility and customisation potential for the end user.
It is also, more generally, desirable to reduce the number of moving parts in the systems in question.
It is also, more generally, desirable to improve the performance of the systems referred to herein with respect to the prior art.
According to an aspect of the present disclosure, there is provided a rivet supply system for supplying rivets to a rivet setting tool comprising a punch for setting the rivets, a nose arrangement defining at least one rivet-receiving zone for receiving the rivets in preparation for setting operations, and a die provided opposite the nose arrangement for reacting the punch, the nose arrangement being movable towards the die to engage with a workpiece, the rivet supply system comprising:
Therefore, the rivet supply system minimizes or does away with any lengths of flexible feed tubing.
Where it is said that at least one rivet transfer device is for holding or releasing (or configured to hold or release) the rivets received at the rivet-receiving zone, the at least one rivet transfer device may be configured to hold, and subsequently release, the rivets received at the rivet-receiving zone;
The rivet-receiving zone refers to a zone in which a rivet awaits transfer under the punch in preparation for a setting operation.
The delivery track (and hence rivet delivery track length) is upstream of the rivet-receiving zone. The rivet transfer device is upstream of the rivet-receiving zone.
Optionally the magazine further comprises the rivet transfer device. Optionally the rivet transfer device is disposed at a distal end of the magazine.
The rivet supply system may be adapted to be operated by gravity.
The rivet supply system may be adapted to be operated by suction generated by a vacuum pump.
The docking interface may comprise an inlet for receiving the rivets which is fluidly open to atmosphere.
The magazine may be removably supported on the setting tool and/or on a C-frame that supports the setting tool.
The magazine may be replaceably supported such that a replacement magazine can replace said replaceable magazine.
The magazine may otherwise be permanently installed on the setting tool.
The system may comprise two such magazines and two such undeformable lengths disposed in mirror configuration on opposed sides of the setting tool.
Each magazine may comprise a first elongated body part extending generally parallel to an axial direction defined by the punch and/or the setting tool.
Each magazine may comprise a second elongated body part disposed downstream of the first elongated body part and angled towards said nose arrangement.
Said first and/or second elongated body parts may comprise at least a portion of said undeformable rivet delivery track length.
The first elongated body part of the magazine and/or the magazine portion of the rivet delivery track may be substantially parallel to said axial direction.
The rivet supply system may further comprise a chute, the chute comprising a chute portion of the rivet delivery track which comprises at least part of said substantially undeformable rivet delivery track length, wherein the magazine is in rivet-supply relation with the nose arrangement via said chute.
The magazine may be directly coupled to the chute.
The magazine and the chute may be coupled via a flexible feed tube.
The magazine may be pivotally supported on the setting tool.
The magazine may comprise multiple independent magazine portions of the rivet delivery track.
The multiple rivet delivery track portions may be selectable for supplying the rivets to the rivet-receiving zone according to corresponding angular orientations of the magazine on the setting tool.
At least one of the multiple rivet delivery track portions may have a curved longitudinal extension to facilitate the refilling of the rivets into the magazine and/or the supply of the rivets from the magazine to rivet receiving zone in the nose arrangement.
At least two of the multiple rivet delivery track portions may be provided with said curved longitudinal extension.
The respective curves may define opposed concavities that tend to converge towards a pivot of the magazine.
The pivot may be generally located at a centre of the magazine.
The magazine may comprise three of said multiple rivet delivery track portions.
The three portions may comprise a first straight portion extending substantially longitudinally. The second and third portions may have said curved longitudinal extensions. The second and third portions may be disposed on either side of the first portion.
The magazine may comprises two or more rivet handling devices each associated with one of said multiple magazine rivet delivery track portions for selectively stopping, trapping and/or releasing one or more rivets on the respective magazine portion of the rivet delivery track.
The rivet handling devices may be disposed at a distal end of the magazine.
The rivet handling devices may each be in the form of an actuated in-line rivet selection device.
The actuated in-line rivet selection device may comprise a rotary cam escapement for selectively stopping, trapping and/or releasing one or more rivets on the respective magazine portion of the rivet delivery track based on a rotation angle of the rotary cam escapement.
The rotary cam escapement may comprise a rotatable cam member for selectively stopping, trapping and/or releasing one or more rivets on said respective magazine portion of the rivet delivery track based on a rotation angle of said rotatable cam member.
The rotatable cam member may comprise an arcuate cam.
The actuated in-line rivet selection devices may be each resiliently biased to a default configuration.
The default configuration may optionally be a default rotary configuration of the rotary cam escapement and/or of the rotatable cam member, for stopping and/or trapping the rivets on said respective magazine portion of the rivet delivery track.
Each rivet handling device may be generally disposed at a distal end of the magazine.
Each rivet handling device may be configured to be actuated via an actuated pin mechanism disposed on said chute.
The actuated pin mechanism may be received on corresponding one or more apertures also provided at the distal end of the magazine.
The actuated pin mechanism may be configured to register the magazine in place according to a predetermined angular orientation.
The actuated pin mechanism may be configured to actuate the rivet handing device.
The magazine may comprises at least one rivet handling device associated with the magazine portion of the rivet delivery track for selectively stopping, trapping and/or releasing one or more rivets.
The one or more rivets may be stopped, trapped and/or released on said rivet delivery track portion.
The rivet handling device may be located at a distal end of the magazine.
The rivet handling device may be in the form of an active in-line rivet selection device.
The active in-line rivet selection device may be as described hereinabove.
The active in-line rivet selection device may be resiliently biased to a default configuration.
The default configuration may be a default rotary configuration of the rotary cam escapement and/or of the rotatable cam member and/or of the arcuate cam, for stopping and/or trapping one or more rivets.
The rivet handling device may be generally disposed at a distal end of the magazine.
The rivet handling device may be configured to be actuated via an actuated pin mechanism disposed on said chute and received on a corresponding aperture also provided at the distal end of the magazine.
The actuated pin mechanism may be configured to register the magazine in place.
The actuated pin mechanism may be configured to actuate the rivet handing device.
The rivet handling device may be disposed part-way along the magazine portion of the rivet delivery track.
The system may comprise two or more independent magazine portions of the rivet delivery track.
Two or more independent rivet handling devices may be associated one with each of the two or more magazine portions of the rivet delivery track for selectively stopping, trapping and/or releasing one or more rivets.
The one or more rivets may be stopped, trapped and/or released on the two or more portions.
The two or more independent magazine portions of the rivet delivery tracks may be upper magazine portions.
The upper magazine portions may be configured to supply rivets to a common lower segment of the rivet delivery track.
At least part of said common lower segment of the rivet delivery track may be disposed within the magazine.
The magazine may comprise an actuated track selection device for selecting one of the two or more independent upper magazine portions of the rivet delivery tracks for supplying the rivets to said common lower segment of the rivet delivery track.
The magazine may comprise a docking device disposed at the docking interface for permitting or inhibiting refilling of the rivets into the magazine from the bulk-supply apparatus.
The docking device may be a passive in-line rivet release device adapted to permit said refilling when the magazine is docked to the bulk-supply apparatus.
The docking device may be adapted to inhibit flow of refilled rivets out of the magazine when the magazine is undocked from the bulk-supply apparatus.
The passive in-line release device may comprises at least one resiliently biased jaw member disposed on a side of the magazine portion of the rivet delivery track.
The release device may be disposed at a proximal end of the rivet delivery track and/or at a proximal end of the magazine.
The passive in-line release device may comprise a pair of opposed resiliently biased jaw members.
The resiliently biased jaw members may be disposed on opposed sides of the magazine portion of the rivet delivery track.
The resiliently biased jaw members may be disposed at a proximal end of the rivet delivery track and/or of the magazine.
The system may further comprise a docking block comprising one or more delivery or feed tubes for connecting the magazine to the bulk-supply apparatus.
The docking block may be adapted to dock with said magazine via said docking interface.
The delivery or feed tubes may be flexible, rigid or semi-rigid.
The rivet transfer device may be a passive in-line rivet release device adapted to hold or release the rivet at the rivet-transfer zone. The rivet transfer device may be a passive in-line rivet release device adapted to hold, and subsequently release, the rivet at the rivet-transfer zone.
The rivet release device may comprise at least one resiliently biased jaw member as described herein. The resiliently biased jaw member may be disposed on a side of the rivet delivery track. The resiliently biased jaw member may be disposed at a distal end of the rivet delivery track.
The rivet transfer device may be in the form of an active in-line rivet selection device configured to selectively stop, trap and/or release one or more rivets at the rivet transfer zone.
The rivet selection device may comprise a linear-pin escapement.
According to an aspect of the present disclosure, there is provided a machine for setting rivets comprising the rivet supply system as described herein.
According to an aspect of the present disclosure, there is provided a method of supplying rivets to a rivet setting tool having a punch for setting the rivets, a nose arrangement defining at least one rivet-receiving zone for receiving the rivets in preparation for setting operations, and a die provided opposite the nose arrangement for reacting to the punch, the nose arrangement being movable towards the die to engage with a workpiece, the method comprising:
According to an aspect of the present disclosure, there is provided a refillable replacement magazine for storing and supplying rivets to a rivet setting tool having a punch for setting the rivets, and a nose arrangement for receiving the rivets in preparation for setting operations, the magazine comprising:
The magazine may be adapted to be directly coupled to the nose arrangement.
The magazine may be adapted to be couplet to a chute.
The chute may be directly coupled to the nose arrangement.
The nose arrangement may be movable and the magazine may be adapted to be supported so as to be moveable together with the nose arrangement generally in the direction defined by the punch.
The magazine may be adapted to be supported on the setting tool and/or on a C-frame for supporting the setting tool.
The magazine may be adapted to be slidably guided within a bracket provided on, or supported by, the C-frame as the magazine moves together with the nose arrangement.
To move the rivets within the magazine, the magazine may be adapted to accept as a rivet motive force:
The suction may be originated by a vacuum pump in fluid communication with the rivet delivery track at the distal end of the magazine.
The magazine may thus be unsealed.
The magazine may comprise a first elongated body part extending generally longitudinally.
The rivet delivery track may also extend generally longitudinally through said first elongated body part.
The magazine may comprise a second elongated body part disposed downstream of the first elongated body part and forming an angle therewith.
The angle may be more than 90 degrees and less than 180 degrees.
The first and second elongated body parts may be connected by a curved elbow.
The magazine may comprise a pivotal attachment for attaching the magazine to the setting tool.
The magazine may comprise two or more of the rivet delivery tracks.
The rivet delivery tracks may be independent and may be arranged to be selectable for supplying the rivets to the nose arrangement depending on an angular orientation of the magazine on the setting tool.
At least one of said multiple rivet delivery tracks may have a curved longitudinal extension to facilitate the refilling of the rivets into the magazine and/or the supply of the rivets from the magazine towards the nose arrangement.
At least two of said multiple rivet delivery tracks may have the curved longitudinal extension, and the respective curves have opposed concavities tending to converge towards said pivot attachment.
The pivotal attachment may be generally located at a centre of the magazine.
The magazine may comprise three of said multiple rivet delivery tracks.
The three tracks may comprise a first straight track extending substantially longitudinally.
The second and third tracks may have the curved longitudinal extensions and may be disposed on either side of the first track.
The magazine may comprise two or more rivet dispensing devices each associated with one of said rivet delivery tracks.
The rivet dispensing devices may be each in the form of a rivet handling device for selectively stopping, trapping and/or releasing one or more rivets on a respective track as described herein.
Alternatively, the rivet dispensing device may be in the form of a rivet handling device associated with the rivet delivery track for selectively stopping, trapping and/or releasing one or more rivets on said track as described herein.
Alternatively, the rivet dispensing device may be in the form of a passive in-line rivet release device adapted to hold or release the rivet to the nose arrangement as described herein.
The magazine may further comprise a rivet handling device disposed part-way through the rivet delivery track for selectively stopping, trapping and/or releasing the rivets on said track as described herein.
The rivet handling device may define upper and lower portions of the rivet delivery track.
The magazine may comprise two or more independent upper portions of the rivet delivery track.
Two or more respective rivet handling devices may each associated with one of the independent upper portions.
The magazine may be configured such that said two or more independent upper portions can each feed one or more rivets onto the lower portion of the rivet delivery track.
The magazine may comprise an actuated track selection device for selecting one of the two or more independent upper rivet delivery track portions to supply the one or more rivets to the lower portion of the rivet delivery track.
The docking device may be in the form of a passive in-line rivet release device. This device may be adapted to permit said refilling when the magazine is docked to the bulk-supply apparatus. This device may be adapted to inhibit flow of refilled rivets out of the magazine when the magazine is undocked from the bulk-supply apparatus.
The rivet release device may comprise at least one resiliently biased jaw member as described herein. This may be disposed at the proximal end of the magazine.
The magazine may comprise one or more magnetically patterned surfaces.
The magazine may comprise a patterned magnet, which may be a permanent magnet.
The magnetically patterned surface may be a first correlated-magnets surface for magnetic interaction with one or more second correlated-magnets surfaces. These may be disposed on a support structure for supporting the magazine. The support structure for supporting the magazine may be provided on the setting tool. Alternatively, the support structure may be provided as an independent support structure, other than the setting tool.
According to an aspect of the present disclosure, there is provided a rivet supply system comprising the magazine as described herein.
According to an aspect of the present disclosure, there is provided a rivet setting tool comprising the rivet supply system as described herein.
According to an aspect of the present disclosure, there is provided a method of supporting the magazine, the method comprising:
According to an aspect of the present disclosure, there is provided apparatus for replacing a rivet or other fastener magazine on a rivet or other fastener setting tool, the apparatus comprising:
The first and/or second support structures may be fixed support structures.
The magazine may be a rivet magazine.
The setting tool may be a rivet setting tool.
The fixed support structures may comprise one or more stands or posts.
The stands or posts may be grouped to form one or more racks for supporting a plurality of magazines.
The one or more stands or posts may be remote stands or posts for refilling the magazines from a bulk-supply apparatus.
The first and/or second support structures may be movable support structures. The movable support structures may be provided on one or more carousels. Each carousel may be adapted to support a plurality of magazines.
The setting tool may comprise one or more brackets adapted to support the first magazine on the setting tool.
The first magazine may be adapted to be magnetically supported on said brackets.
A pair of correlated-magnets surfaces may one be provided one on an external surface of said first magazine, and the other on at least one of said brackets.
The setting tool may comprise a C-frame.
The setting tool and the C-frame may be mounted on the robotic arm.
At least one of said brackets may be disposed on said C-frame.
The one or more brackets may be disposed on a longitudinally extending body portion of the C-frame.
The first magazine may be disposed in a rivet supply engagement on the setting tool.
The setting tool may comprises a punch for setting the rivets, a nose arrangement for receiving the rivets in preparation for setting operations, and a die provided opposite the nose arrangement for reacting the punch.
The nose arrangement may be movable towards the die to undock the first rivet magazine from the rivet supply engagement on the setting tool, thereby facilitating the transfer of the first rivet magazine from the setting tool to the first support structure.
The first rivet magazine may be supported so as to be movable together with the nose arrangement.
The nose arrangement may be movable towards the die to undock the first rivet magazine from rivet supply engagement on the setting tool when the first rivet magazine is supported on the first support structure.
The first and/or second magazine connection features may each comprise a magazine plate-like structure.
The magazine plate-like structure may be in the form of a magazine pad provided on said magazine.
The magazine pad may comprise a layer of a compliant material.
The magazine plate-like structure may be grooved or ridged so as to form a key-like profile.
The magazine plate-like structure may be magnetic.
The magazine magnetic plate-like structure may comprise a permanent magnet.
The magazine magnetic plate-like structure may comprise a magnetically patterned surface.
The first and second complementary connection features may each comprise a support plate-like structure.
The support plate-like structure may be in the form of a support pad provided on said first and/or second support structure.
The support pad may comprise a layer of a compliant material.
The support plate-like structure may be complementarily respectively ridged or grooved with respect to the magazine plate-like structure so as to form a complementary key-like profile.
The support plate-like structure may be magnetic.
The magnetic plate-like structure may comprise a permanent magnet.
The magnetic plate-like structure may comprise a magnetically patterned surface.
The magazine and support plate-like structures may comprise at least one further pair of correlated-magnets surfaces.
The further pair of correlated-magnets surfaces may be adapted to magnetically align the first rivet magazine in place on the first support structure and/or the second rivet magazine in place on the second support structure.
The further pair of correlated-magnets surfaces may be adapted to magnetically latch the first magazine in place on the first support structure and/or the second magazine in place on the second support structure.
The further pair of correlated-magnets surfaces may be adapted to magnetically release the first magazine from the first support structure when the first magazine and the first support structure are brought in misalignment one with respect to the other.
The further pair of correlated-magnets surfaces may be adapted to magnetically release the second magazine from the second support structure when the second magazine and the second support structure are brought in misalignment one with respect to the other.
The apparatus may further comprise at least one further magazine having a further connection feature for connecting the further magazine to a further complementary connection feature different than, and not compatible with, the complementary connection feature related to the first and second magazines, and at least one further support structure located within said work area, said further support structure comprising one such further complementary connection feature.
The further connection features may comprise a pair of magnetically repulsive surfaces.
The magnetically repulsive surfaces may each comprise a magnetically patterned surface.
According to an aspect of the present disclosure, there is provided a method of replacing a rivet or other fastener magazine on a rivet or other fastener setting tool, the method comprising:
According to an aspect of the present disclosure, there is provided a replacement magazine for storing rivets or other fasteners for supply to a rivet or other fastener setting tool, the magazine comprising:
The magazine may have an elongated, generally tubular shape.
At least one rivet delivery track may extend internally through the magazine.
The magnetically patterned surface may be provided on an external surface of the magazine.
The magnetically patterned surface may be provided on a plate-like structure provided on the magazine.
The plate-like structure may be in the form of a magazine pad comprising a layer of a compliant material.
The magnetically patterned surface may be a first correlated-magnets surface for coupling with a second correlated-magnets surface provided on a magazine complement.
According to an aspect of the present disclosure, there is provided a magazine as described herein, in combination with the magazine complement.
The magazine complement may be a magazine refill device.
The refill device may comprise a rivet feed tubular member.
The magazine may comprise a plurality of upper tracks.
The rivet feed tubular member may comprise a corresponding plurality of rivet feed passageways.
The first correlated-magnets surface may be provided on a magazine docking interface provided on the magazine for docking/undocking the magazine to a rivet supply line extending through said magazine refill device.
The magazine docking interface may be provided on an upper face of the magazine.
The magazine docking interface and refill device may be adapted to sealing engage to reduce or prevent air loss therebetween during magazine refill operations that use compressed air as a rivet motive force.
Said second correlated-magnets surface may be disposed on a refill docking interface provided on said refill device.
The refill docking interface may be provided on a lower face of the refill device.
The first and second correlated-magnets surfaces may be adapted to generate an alignment force between the magazine and the refill device upon magnetic engagement thereof, such that rivets can be transferred from the refill device to the magazine.
The first and second correlated-magnets surfaces may be adapted to generate a repulsive release force between the magazine and the refill device upon magnetic disengagement thereof.
The rivet refill device may be supported on at least one compliant mount.
The rivet refill device may be supported on a plurality of compliant mounts.
The rivet refill device may comprise a first support structure and a second support structure, and the one or more compliant mounts may be disposed between respective distal and proximal ends of the first and second support structures.
The first support structure may be a tripod, and the three compliant mounts may be disposed between said tripod and the second support structure.
The first support structure may comprise at least one first rhomboid plate and the second support structure may comprise at least one second rhomboid plate disposed externally with respect to said first rhomboid plate.
The one or more compliant mounts may be adapted to absorb a force generated by contact between the refill device and the magazine when the magazine and the rivet refill device are coupled to refill the magazine with rivets.
The one or more compliant mounts may be adapted to return the refill device to an initial position of equilibrium after that the refill device has been displaced from said initial position of equilibrium.
The refill device may comprise stop means for constraining movement of the refill device within a predetermined range of positions in at least one direction.
The stop means may comprise two spaced apart ring members for limiting vertical positions of the rivet feed tubular member.
The magazine complement may be a chute for docking the magazine to a nose arrangement of the rivet setting tool.
The first correlated-magnets surface may be provided on a magazine docking interface provided on the magazine for docking/undocking the magazine to a rivet supply line extending through said chute.
The magazine docking interface may be provided on a lower face of the magazine.
The second correlated-magnets surface may be disposed on a chute docking interface provided on said chute.
The chute docking interface may be provided on an upper face of the chute.
The magazine complement may comprise a bracket.
The first correlated-magnets surface may be provided on a setting tool-facing side of the magazine.
The bracket may be provided on the setting tool or on a C-frame supporting the setting tool.
The second correlated-magnets surface may be provided on a recess for accommodating the magazine provided on said bracket.
The magazine complement may comprise an independent support structure, other than the setting tool.
The magazine support structure may comprise a support plate-like structure as described herein.
The first correlated-magnets surface may be provided on an outwardly facing side of the magazine.
According to an aspect of the present disclosure, there is provided a method of supporting a replacement magazine on a structure, the method comprising:
The magazine and said structure may be adapted to define a mechanical engagement designed to facilitate said magnetically engaging said surfaces to connect the magazine to said structure, such that the magazine and the structure are mechanically connected in addition to being magnetically connected when the replacement magazine is supported on said structure.
The mechanical engagement may comprise an abutment between said magazine and said structure.
The abutment may comprise first and second complementary key-like profiles provided respectively on the magazine and on said structure.
The first and second key-like profiles may be provided respectively on said first and second magnetically patterned surfaces.
The mechanical engagement may define at least one possible direction for magnetically engaging said surfaces to connect the magazine to said structure.
The mechanical engagement may define a sole direction for magnetically engaging said surfaces to connect the magazine to said structure.
The magnetically patterned surfaces may be adapted to magnetically engage one with the other if said surfaces are spaced apart within a predetermined maximum distance.
The magnetically patterned surfaces may be adapted to magnetically align said magazine and said structure upon engagement.
According to an aspect of the present disclosure, there is provided a method of disconnecting a replacement magazine from a structure, the method comprising:
The magazine and the structure may be adapted to define a mechanical engagement as described herein designed to facilitate said magnetically disengaging said surfaces to disconnect the magazine from said structure, such that the magazine and the structure are mechanically disconnected in addition to being magnetically disconnected when the replacement magazine is disconnected from said structure.
The mechanical engagement may define at least one possible direction for magnetically disengaging said surfaces to disconnect the magazine from said structure.
The mechanical engagement may define a sole direction for magnetically disengaging said surfaces to disconnect the magazine from said structure.
The method may further comprise moving the magazine and/or said structure relative to each other further than a predetermined minimum distance.
The magnetically patterned surfaces may be adapted to magnetically mutually repel said magazine and said structure upon disengagement.
According to an aspect of the present disclosure, there is provided riveting apparatus comprising:
The one or more magazines may be in rivet-supply engagement on the rivet setting tool.
The one or more magazines may be each as described herein.
Each magazine may comprise an electronically readable tag carrying said information.
The reader may comprise an electronically readable tag reader.
The electronically readable tag may be located on a tool-facing side of the magazine.
The electronically readable tag reader may be located on a bracket for supporting said one or more magazines in said rivet-supply engagement on the rivet setting tool.
The rivet setting tool may be mounted on a robotic arm.
The controller may be configured to control the robotic arm.
The magazine may be replaceable.
The controller may be configured to control said robotic arm to carry out a magazine replacement operation.
The controller may be configured to control said robotic arm to carry out a magazine replacement operation as described herein.
The rivet setting tool may comprise a replaceable and/or adjustable die assembly.
The controller may be configured to control the setting tool to replace and/or adjust said replaceable and/or adjustable die assembly.
According to an aspect of the present disclosure, there is provided a method of riveting, the method comprising:
According to an aspect of the present disclosure, there is provided a method of riveting, the method comprising:
According to an aspect of the present disclosure, there is provided a method of riveting, the method comprising:
According to an aspect of the present disclosure, there is provided a method of riveting as described herein, the method further comprising:
According to an aspect of the present disclosure, there is provided a method of manufacturing a vehicle or a part thereof by setting one or more rivets, wherein said method comprises any of the procedures described herein.
The present invention will now be described in connection with the appended drawings in which:
In the present description, first the meaning associated to certain terms or phrases used herein will be introduced. The context of the presently described fastening operations will also be briefly discussed.
Reference will then be made to
Finally,
Introduction
We describe in particular self-piercing rivet setting machines of the type that set self-piercing rivets, for example, on plates of various thicknesses, for manufacturing vehicle bodies such as automobile frames and/or panels. Nonetheless, the skilled person will understand that at least some of the teachings herein are equally applicable to different setting tools, and/or to a more general description of fasteners.
The self-piercing rivet setting machines described herein are usually incorporated into a robotic arm so that they can travel and be positioned where required within a working area, according to many different orientations. To achieve this, a rivet setting tool, which has a punch for setting the rivets, is mounted on a C-frame which is in turn mounted on the robotic arm. The robotic arm may be operable to translate and/or rotate the setting tool according to several degrees of freedom. The robotic arm is only schematically shown in the drawings and will not be described herein in further detail. However, the operation of the robotic arm will be described in some further detail in connection with certain aspects of the present disclosure. It will be apparent that the rivet supply arrangements described herein are particularly suited to setting tools mounted on such C-frames and/or robotic arms.
As described herein, “nose arrangement” identifies the arrangement of the working end of the rivet setting tool. The punch travels through the nose arrangement to guide a rivet towards the workpiece and sets it into the workpiece. The nose arrangements described herein are mounted on a piston/cylinder arrangement operated by a servo mechanism on the setting tool. The nose arrangements described herein are thus movable and extend away from the setting tool to come into contact with the workpiece, thus preparing for a setting operation.
In or adjacent such nose arrangements, there are provided one or more designated “rivet-receiving areas” or “rivet transfer areas” where the rivets (having reached the end of their travel from a bulk feeder, or other-bulk storage system, to the nose arrangement, along the rivet supply system) await so that they can then be, in turn, transferred to a stand-by position under the punch to be set into the workpiece one at a time.
“Nose assembly” identifies a sub-assembly of the nose arrangement that more specifically serves to guide the rivet and the punch, after that the punch has engaged the rivet during a rivet setting operation. The nose assembly is not described herein in detail.
The action of the punch on the workpiece during a setting operation is resisted by a “die assembly” located at a receiving end of the C-frame. Certain die assemblies are described herein in some detail.
As mentioned above, “rivet setting operation” identifies the travel that the punch undertakes for setting a rivet into the workpiece. However, the mechanics of these operations is not described herein in detail since the present specification is mainly concerned with how the rivets are stored, and then supplied to the setting tool, and with how the rivets can be replenished in the magazine(s) when required.
Since the rivet supply systems described herein are suited to the supply of rivets from a bulk-storage apparatus to a setting tool, attributes such as “proximal” and “distal” are generally referred to the one-way direction of travel of the rivets through the supply system. Thus, for example, the “proximal end” of a rivet magazine identifies the end of the magazine where the rivets enter the magazine. The “distal end” of the magazine identifies the end of the magazine where the rivets exit the magazine to or towards the nose arrangement.
The various features shown in the Figures have been assigned reference numerals as customary. For clarity, however, where the same or an equivalent feature has been shown in connection with different arrangements, this feature (at least in the vast majority of cases) has been assigned the same reference numeral.
Multiple instances of the same feature shown in the drawings have been labelled using small-case letters suffixed to the reference numeral assigned to that feature. For example, multiple magazine portions of the rivet delivery track are labelled 11a, 11b, 11c. However, when general reference has been made to that feature, the reference numeral may have been used without the small-case letter suffix. For example, to designate in general said multiple magazine portions of the rivet delivery track reference numeral 11 may have been used.
The self-piercing rivets described herein are labelled with capital letters, for example A, B, C, etc. However, it will be apparent that other fasteners may be suited to be supplied to a setting tool according to the principles described herein. Nonetheless, the fasteners being in the form of rivets or self-piercing rivets are preferred features of at least some aspects disclosed herein.
Different positions or orientations assumed by a given component have been labelled using apexes following the reference numeral assigned to that component, or to a feature identifying said position. For example, the pivotal magazines in the positions shown in
The attribute “independent” with reference to any rivet tracks, or portions thereof, has been used to mean that said independent tracks/portions do not intersect, or otherwise interact with regards to the flow of the rivets therethrough. In other words, these tracks/portions do not share any segments in common. Accordingly, the passage of the rivets in these independent tracks/portions can be independently regulated or controlled on each independent track/portion.
The attribute “independent” with reference to any described external means for supporting the magazines has been used to mean that such means are provided as separate entities with respect to the setting tool, the C-frame and/or the robotic arm on which the C-frame is mounted.
The attribute “passive” referred to a mechanism denotes the absence of a dedicated actuator operated by external means. Thus for example a pair of resiliently biased jaws for controlling the refill of rivets at the proximal end of the magazine are classed as a passive mechanism for the purposes of the present specification even though the jaws are initially biased in a closed position by a set of springs, and can be opened by the abutment (ie coupling, or docking) of the magazine with, for example, a magazine refill device such as a docking block, as will be further described herein.
The attribute “active” referred to a mechanism instead denotes the presence of a dedicated actuator operated by external means (eg an electric servo-mechanism, or a pneumatic mechanism operated by pneumatic lines) to control the position and/or the configuration of one or more elements of the mechanism itself according to an external command or signal. Thus for example a rotary cam mechanism that operates on a rivet delivery track to selectively release one or more rivets on said track upon operation of a dedicated actuator, which is in turn operated upon receipt by a controller or the like of an appropriate signal or command, is classed as active.
The term “replaceable” refers to a rivet magazine disposed in rivet-supply relation or rivet-supply engagement in the rivet supply line, and which can thus be removed to be replaced, ie substituted, with another identical or similar magazine, for example with another magazine which stores rivets, of the same or a different type, while the replaceable magazine is empty. This other magazine is instead referred to as a “replacement” magazine. The attribute “replacement” when used in conjunction with one or more magazines thus denotes one or more magazines that are ready for replacing a replaceable magazine, for example because the replaceable magazine is empty (for example because all of the fasteners initially stored therein have been used) and the replacement magazine is full, or partly full. It is understood that examples are not limited to the replacement of a replaceable, empty magazine with a replacement, full magazine. Alternatively, it may be necessary to substitute a partially full magazine with a magazine storing rivets of a different type and/or size, as a requirement for example of a particular fastening sequence. The replacement magazine may be full, or may have been only partly filled with the rivets. Alternatively, the substitution may be between an operable magazine and a magazine which is known to have been damaged, or which cannot operate, for any occurring reasons.
Each magazine described herein, in its most basic form, is a generally elongated tubular structure with a portion of the rivet supply line that runs internally through it. The rivets can thus be stored, as a line or a queue, in the magazine and, when required, can be released from the magazine to supply the setting tool. The cross-sectional shape of the rivet supply line described herein is a “T-shape” adapted to generally conform, with clearance, to the shape of the self-piercing rivets described herein. The rivets thus travel generally transversally with respect to the generally longitudinal extension of the rivet supply line through the magazine. However, other cross-sectional shapes are in principle possible, and these will mainly depend on the shape and/or dimension of the fasteners. Further, the rivets, or other types of fasteners, could in principle be made to travel maintaining a longitudinal orientation rather than travelling transversally. However, in the self-piercing rivet fastening applications described herein this alternative may not be preferred.
The magazines described herein are generally constructed by joining together back and front plate members each formed with suitable grooves to obtain the T-shaped cross sections of the rivet delivery tracks when the plate members are joined together to form the magazines. We will not provide any additional details relating to the specific construction of the magazines throughout this description, but, as will be apparent, a variety of magazine designs, constructions and materials are possible, including traditional materials, such as metals, including ferromagnetic metals, or non-ferromagnetic materials such as suitable polymeric materials.
The magazines, and other accessory structures described herein, may include one or more “patterned magnets”, that is magnets having surfaces patterned with regions characterized by opposed magnetic polarities or signs (ie “north” and “south”, or “plus” and “minus”) as a result of magnetic structures (ie magnetic domains) arranged in alternate order within the patterned magnets.
Patterned magnets concentrate their resulting magnetic field closer to their surface than traditional magnets. Patterned magnets may thus be used to generate dense, local magnetic fields which may be used to strongly attract a ferromagnetic material disposed in close proximity to said magnets without affecting other spaced away ferromagnetic elements. The exposed surfaces of these patterned magnets are referred to herein as “magnetically patterned surfaces”.
It is possible to arrange the above patterns/surfaces to achieve different resulting magnetic fields. It is thus also possible to program pairs of magnetically patterned surfaces to generate location-dependent forces to achieve various desired mechanical effects between such magnets and, therefore, between the structures that accommodate such magnets. We thus also refer to these pairs of patterned magnets as “correlated” magnets or “programmed” magnets. Pairs of “correlated” magnetically patterned surfaces or “complementary” magnetically patterned surfaces of this type may thus be designed to achieve a variety of mechanical performances that go beyond simple magnetic attraction, or magnetic holding force. We describe herein certain mechanical performances that can be obtained by providing suitable pairs of magnetically correlated surfaces which are advantageous, for example, in applications such as docking a rivet magazine to a refill station, or to a setting tool, or supporting a rivet magazine on a support structure provided on the setting tool, or elsewhere. These magnetically correlated patterned surfaces are also referred herein as “correlated-magnets surfaces”, because of their mutual magnetic correlation. Reference is made to the research carried out by Larry W. Fullerton about a decade ago, the results of which are known from literature, including from patent literature.
For the purposes of the present description, magnetically correlated surfaces or correlated-magnets surfaces may be obtained in a number of different manners, including using permanent magnets, electromagnets or other equivalent field emission structures (although the latter may be less preferred in the rivet fastening applications described herein). Further, such correlated-magnets surfaces may vary widely as regards the specific geometry of their patterns. Moreover, such surfaces can be part of one or more magnetic inserts, such as one or more patterned magnets incorporated into, for example, the magazines. Alternatively, as mentioned above, they can potentially be induced (in a way akin to ‘printing’) on any of the magazine surfaces, if the magazines are made, at least partly, of a ferromagnetic material.
Induced or printed individual magnetic elements (also known as “maxels”) may thus be arranged to form correlated pairs of patterned magnets that interact via their correlated-magnets surfaces. These magnetically correlated surfaces can be designed to achieve the desired mechanical functions and can have different sizes, and be disposed in a number of different ways. It is not within the scope of the present application to describe any particular patterns or geometries related to said correlated-magnets surfaces and their mechanical functions. Instead, it is noted that adequate patterned magnets for forming pairs of useful correlated magnets can readily be purchased, for example, from Correlated Magnetics Research, LLC, at the time of writing the present specification from website www.polymagnet.com. Suitable correlated-magnets surfaces may otherwise be fabricated.
Product reference 1001107 from www.polymagnet.com, for example, is a two-dimensional (2D), one inch-square alignment patterned magnet which can be paired with another patterned magnet of the same type via opposed faces having complementary (ie correlated) polarity patterns. Thus one face has a given polarity pattern on the one patterned magnet, and the opposed paired face has a corresponding, negative-image polarity pattern on the other patterned magnet. Pairs of 1001107 correlated magnets can thus provide a two-dimensional alignment function with a holding force and an alignment shear resistance. This means that when the correlated-magnets surfaces of these patterned magnets are perfectly aligned, a holding force perpendicular to the magnetically engaged surfaces of the 2D magnets is generated together with a small, or null, alignment (shear) force. When the magnets are brought out of alignment (this can be done with a relatively small force), starting from the position of perfect alignment, the holding force decreases. Simultaneously, the alignment force increases and tends to realign the magnets.
Contact between engaged magnetic surfaces is not a requirement for magnetic interaction between a pair of correlated magnets, although contact may be a preferred feature. For example, holding perpendicular and shear forces of similar magnitude between the correlated magnets described above would nevertheless be generated if a small gap was present between the respective magnetically correlated surfaces. However, the resulting forces would be correspondingly weaker. This could be the case if a layer of a protective or compliant material, such as a protective film, was used to coat the correlated-magnets surfaces. The mechanical performance of the correlated magnets may also be affected by other characteristics, for example the presence and/or size of a layer of backing material disposed on the back of the correlated magnets.
Pairs of different correlated magnets having different magnetically correlated surfaces provide different mechanical functions defined by different sets of magnetically generated forces which depend on the relative positioning between the correlated magnets as well as on the actual shape of the patterns. Note that to achieve some of these function, the correlated magnets may have to be constrained in at least one degree of freedom.
The magnetically generated mechanical forces described herein may fulfil different functions including “alignment”, as seen above in the case of correlated magnets 1001107. However, other possible mechanical functions may also be useful for the purposes set forth in the present description, for example:
The above list is not exhaustive. For example, similar functions are contemplated which relate to angular positioning, or degree of rotation, between the correlated magnets (eg “torsional alignment”, “torsional spring” or “torsional latch”).
It will further be appreciated that the above general mechanical behaviours are not mutually exclusive in that a given pair of correlated magnets may simultaneously behave according to multiple behaviours at a given time, depending on the relative positioning between the magnets.
As mentioned above, importantly the mechanical behaviour of correlated magnets generally changes with the relative positioning of the magnets to provide an overall ‘mechanical experience’. At any given position, however, one of the above behaviours may be predominant. Within the scope of the present application, various possible practical uses of mechanical performances described in connection with and achieved by pairs of correlated magnets are presented, within the broad context of fasteners supply and storage applications.
“Docking interface” as used herein refers to a surface of a component (this could be for example the magazine) that has appropriate features to establish a rivet-supply communication with another component presenting a corresponding or complementary docking interface provided on that other component. The term “docking”, therefore, is in the present description always used in connection with at least one rivet supply track. For example, a rivet supply track may be disposed in rivet-supply relation with a bulk-supply apparatus by docking the magazine directly to the bulk-supply apparatus, or by docking the magazine to an intermediate docking device that has a suitable docking interface. This docking device could, for example, be a docking block connected to the bulk-supply apparatus via one or more lengths of flexible tubes.
When instead mechanical connections are more generally described for the purpose of supporting a component, for example a replacement magazine, on a support structure such as a stand, general terminology such as “support”, “supported”, “connection”, “connected”, or more specific terminology indicating the manner of said support or connection such as “latch”, “latched”, “guide”, “guided” is used. Thus, a replacement magazine may be supported on a stand while it is in non-rivet supply relation within a rivet supply line, for example while the magazine is not docked to the rivet supply line. To support the magazine on the stand, a magnetic pad may for example be provided on the magazine. The magnetic pad may comprise a patterned magnet. The stand may comprise a correlated patterned magnet. Alternative supporting means are however also possible. To dock the magazine to the nose arrangement, a U-shaped guide may for example be provided on the C-frame to guide the magazine in a direction substantially parallel to the punch.
A number of passive and active rivet handling devices are described herein which serve a variety of purposes at different stages of the progress of the rivets through a rivet delivery line. It is not within the scope of the present application to describe these devices in detail. However, their role in connection with the handling of the rivets through the rivet supply line will be described.
The first type of rivet handling devices encountered henceforth can be defined as “active in-line rivet selection devices”. These devices are actuated via an external actuator and their purpose is, at the required time, to release a selected rivet on the rivet delivery track. Examples of active in-line rivet selection devices are “rotary cam escapements” and “linear pin escapements”. Both will be briefly described herein. The main difference between these two types of devices is that the rotary cam escapement utilises rotary actuation of a cam device to release the selected rivet, while the linear pin escapement utilises linear actuation to move one or more pin-shaped barriers to release the selected rivet. The cam devices and pin-shaped barriers can in principle have many different forms, and some are described herein in some detail.
The second example of rivet handling devices briefly described herein can be defined as “active track selection devices”. These devices are also actuated via an external actuator and their purpose is to connect one or another of multiple upper portions of a rivet delivery track to a common, lower portion of the rivet delivery track within the magazine. An example of an active track selection device is a “rotary track selector”. In the rotary track selector, a rotary member rotates to join one of many possible upstream portions of the rivet delivery track with a common downstream portion of the rivet delivery track via a curved rivet delivery track portion located in the rotary selector, so that rivets can be transferred from the selected upper (or upstream) track to the common lower (or downstream) track. However, different active track selection devices would be possible.
The third type of rivet handling devices briefly described herein can be defined as “passive in-line rivet release devices”. These devices are not actuated in the sense required by the devices identified above. Rather, these passive devices are by default biased to a default position, such as a close position. Depending on their use, in the closed position these devices may, for example, prevent one or more rivets from exiting the magazine, or may prevent one or more rivet from entering the magazine. These devices may be switched to their open position by, for example, contact of the magazine with other mechanical parts of the system designed to cooperate with the magazine, for example with a rivet transfer device provided in the nose arrangement, or a docking interface, to respectively transfer a rivet in the stand-by position under the punch, or to refill the magazine with fresh rivets.
It will by now be clear that the emphasis of the present patent specification is on the storage and supply of rivets in proximity of the setting tool. A complete rivet supply line usually extends from the bulk-storage apparatus to the setting tool. However, we do not focus on the bulk-supply end of such rivet supply lines. Rather, we focus on the last portion of these rivet supply lines, close to the setting tool, and we provide at least one (typically removable and replaceable) magazine to store a quantity of rivets close to the setting tool. The magazine(s) are, in use, in rivet-supply relation with the nose arrangement of the setting tool. It is thus possible, and in some cases preferable, to mount the magazines so that they are supported by the nose arrangement, which is part of the setting tool. The setting tool is, however, ultimately supported by the C-frame, and the magazine(s) is/are also, therefore, ultimately supported by the C-frame.
The C-frame usually incorporates appropriate brackets, guides or other like mechanical elements to guide and facilitate docking between a magazine and the nose arrangement, or between the magazine and an accessory such as a chute or the like, disposed between the magazine and the nose arrangement. Further, following a reverse sequence, these components may also facilitate the replacement of a docked magazine. In this way, the replaceable magazine is undocked from the setting tool. These support components may be provided according to a large variety of designs. Only a few such designs are described herein in some detail. A further function of these brackets is, in preferred designs, to guide the magazine so that the magazine is adequately supported when it moves in unison with the nose arrangement to prepare for a setting operation. This will be further described below.
Referring now to
The setting tool 2 comprises a nose arrangement 4 that defines at least one rivet-receiving zone or rivet-transfer zone 5a, 5b within or adjacent to it. Here, two rivet-transfer zones 5a, 5b are defined on, respectively, the left-hand side and the right-hand side of the setting tool 2 as shown in
Two magazines 10a, 10b are provided in mirror configuration on the left and right-hand sides of the setting tool 2 as shown in
At the distal ends 13a, 13b of the chutes 16a, 16b, two passive in-line rivet transfer devices (not shown in
Each rivet delivery track 8a, 8b thus extends through a corresponding magazine 10a, 10b and, further, through the corresponding chute 16a, 16b, if the chutes 16 are provided. It is accordingly possible to identify a magazine portion 11 of the rivet delivery track 8 in each magazine 10. In the arrangement shown in
Each magazine 10a, 10b defines at its proximal end 15a, 15b an upper docking interface 12a, 12b for refilling the magazine 10a, 10b from a bulk-storage apparatus (not shown). The magazines 10 can thus be refilled in-situ, if required, by docking the magazines 10 to the bulk-storage apparatus via the upper docking interfaces 12 according to any one of various possible refilling procedures, some of which will be described in the paragraph below.
A docking block 70 (one is shown in
As can also be seen in
The magazines 10 are supported on the setting tool 2 and on the C-frame so as to be movable together with the nose arrangement 4 to prepare a setting operation. At the distal ends 20a, 20b, the magazines 10a, 10b are each connected to the proximal end 17a, 17b of the respective chute 16a, 16b. The chutes 16 are rigidly connected to the nose arrangement 4 so that when the nose arrangement 4 moves towards the die assembly 6, the nose arrangement 4 causes the magazines 10 to move with it in direction “v” shown in
A set of brackets 18 attached to each chute 16a, 16b is provided to dock the magazines 10 to the respective chutes 16. These brackets 18 move with the nose arrangement 4, guided by a pair of C-shaped brackets 19 attached to the upper working end 9 of the C-frame 3 on either side of the setting tool 2. The brackets 18, 19 ensure that each magazine is adequately maintained in rivet-supply engagement with the chute 16 as the nose arrangement 4 is moved to prepare for a setting operation, as shown in
In the described arrangement, therefore, on each side of the setting tool 2 a complete rivet delivery track 8, that is a magazine portion 11 of the rivet delivery track 8 and a chute portion 33 of the rivet delivery track 8, moves in unison with the nose arrangement 4 to prepare for a setting operation. Accordingly, there is no requirement for any flexible tubing, at least downstream of the upper docking interfaces 12 of the magazines 10.
Further, the setting tool 2 may perform multiple riveting operations with continuity of supply from the magazines 10 without retracting, or without fully retracting, since the rivet-supply engagement with the magazines 10 is always maintained.
In other arrangements, the magazines 10 may be supported so as not to follow the movement of the nose arrangement 4, in other words so as to be fixed relative to the setting tool 2 and/or the C-frame 3. For example, the magazine(s) 10 may be mounted on the C-frame 3. These magazine(s) 10 can still be operated to release and feed one or more rivets to the chutes 16. However, they can only do so when the magazine(s) 10 are docked to the chute(s) 16. The rivets can then wait at the rivet-receiving zone(s) 5, and thereafter the nose arrangement 4 can be moved in unison with the chute(s) 16 to prepare for setting operations, without displacing the magazine(s) 10. In this case, only a limited number of riveting operations are possible before the nose arrangement 4 has to be fully retracted to load more rivets.
In other arrangements, small lengths of flexible, semi-rigid or rigid delivery tubing may be used between the magazine(s) 10 and the chute(s) 16. In these arrangements, however, the magazine(s) and the chute(s) would move together with the nose arrangement 4 when the nose arrangement 4 is extended. The delivery tubing would move accordingly with the magazine(s) and the chute(s) as a single body, or it could accommodate a differential movement between the magazine(s) and the chute(s), including in the case when the magazine is fixed with respect to the tool and the chute moves with the nose arrangement. Alternative chute arrangements than those illustrated and described herein could be devised. For example, the chute(s) could be arranged perpendicularly with respect to the punch axis and could include a substantially right angle bend to dock with the magazine(s).
The magazines 10 described herein are replaceable in that they can be removed from the respective chutes 16 and supports 18, 19 provided therefor on the setting tool 2 and the C-frame 3. Referring now to
The operation of the rotary cam mechanism 31 of
Referring now to
The leading rivet A′ can also be “trapped” rather than “stopped” by the arcuate cam 29 in the leading rivet position following a slight anti-clockwise rotation from the default configuration shown in
If inversion of the setting tool 2 is not contemplated, then the trapping function may be redundant and the rotary cam mechanism 31 is operated in binary fashion as follows:
Accordingly, the leading rivet A′ is released and the trailing rivet A″ (and any other queuing rivets) is stopped by the arcuate cam 29.
Considering now
To facilitate the initial alignment of the magazine 10b with the chute 16b, the elongated body 34b of the magazine 10b is received in a U-shaped portion 35b of the brackets 18 provided with the chute 16b. The magazine 10b can then be smoothly guided down until docking is complete. Alternative or additional features for facilitating the docking of the magazine 10b onto the chute 16b are possible, for example utilising patterned magnets on the magazine 10b and/or on the chute 16b, or on the magazine 10b and/or on the brackets 18, or correlated magnets between the magazine 10b and the chute 16b, or between the magazine 10b and the brackets 18. These features may include coupling, alignment and/or latching via respective correlated magnets surfaces. One example will be described in more detail in connection with
To undock the magazine, the reverse sequence is applied, for example as described by referring sequentially to
An external pad 36b provided about half-way along the magazine 10b as seen in
A colour coded label, bar code or other Poka-Yoke feature (including one or more fully mechanical, electro-mechanical or electronic Poka-Yoke features) may alternatively be provided elsewhere on the magazine. For example, a fully mechanical Poka-Yoke feature could be provided by the fit (or lack thereof) between the distal end 20 of the magazine 10 and the proximal end 17 of the chute 16. Accordingly, certain chutes 16 could be adapted such that the setting tool 2 may only accept certain types of magazines 10 corresponding to predetermined types and/or sizes of rivets. Alternatively, the brackets 18 supporting the magazines 10 on the setting tool 2 could be so adapted.
As another example, a rivet information reader 201 in the form of an electro-mechanical rivet check device may be provided on the setting tool 2 as shown in
The controller 1203 can be the controller of the robotic arm 200, or a separate controller that is however operatively coupled to the robotic arm 200. In its most basic form, the controller 1203 will include a processor and a memory. These details are not however discussed further in this disclosure. The skilled person will, however, recognise that a large variety of suitable controllers are possible, for example including one or more personal computers, which could be dedicated to the operation of the robotic arm 200 or that operate the robotic arm 200 in addition to other machines (such as the fastener setting tool 2 and/or bulk feeder apparatus). Further, the controller 1203 and the reader device 201 could be provided as parts of a same machine, or could be implemented on different machines in communication between them.
Said one or more signals issued by the rivet information reader 201 may be representative of a condition of the setting tool 2 whereby the setting tool 2 is capable of delivering the rivets required for a predetermined setting operation. This is, in the present disclosure, associated with the capability of the rivet setting tool 2 to read rivet type and/or size information from the correct magazine 10 docked to the setting tool 2. This capability is implemented by the presence of the rivet information reader 201 described herein. Alternatively, said one or more signals issued by the rivet information reader 201 may be representative of a condition of the setting tool 2 whereby the setting tool is not capable of delivering the correct rivets. This is, in the present disclosure, associated with an incorrect magazine 10 being docked on the setting tool 2. Note that it may be possible to adapt the rivet information reader 201 such that absence of any signals generated by it may signify a correct or incorrect fastener type and/or size being stored in the magazine 10 loaded on the setting tool 2.
The magazine controller 1203 is configured to receive and interpret any information received from the rivet information reader 201. In response thereto, if the fasteners stored in the magazine 10 are not of the type and/or size required for a current fastening application, the controller 1203 generates one or more signals (again, this may include a nil signal) to instigate the robotic arm 200 to undertake a magazine replacement operation as described herein. If instead the magazine 10 in question is correct (ie it stores one or more rivets of the type and/or size required in the instant fastening operation), then the controller 1203 may issue one or more signals that positively support a fastener setting operation. For example, the controller 1203 may issue a signal triggering a fastener setting operation as described herein. Alternatively, the controller 1203 may issue a signal triggering motion of the robotic arm 200 for relocating the setting tool 2 to a location where the installation of a rivet is required, or a signal signifying that any one of the above operations can be carried out by the robotic arm 200 and/or setting tool 2 at a later moment. In this case, the system has recognised that the correct rivet is available and thus the system is not inhibited from carrying out rivet setting operations. In other words, it is not necessary to first replace (or refill) any of the magazines 10 docked to the setting tool 2. These signals are schematically represented by the arrow pointing to the right in
As it will be apparent, electronic Poka-Yoke features may be preferred. For example, to check the appropriateness of a tool-mounted magazine 10 in respect of a current or ongoing fastening operation, a rivet information reader 201 in the form of a bar code reader, or RFID reader, could be used. In this case, the magazines 10 would correspondingly have to be bar code tagged or RFID tagged. For example, in
Any of the above measures may contribute to ensure security of rivet type supply—provided that the magazines have correctly been filled with the intended type and/or size of rivets or other fasteners.
With reference to
In
An undocking procedure for undocking the right-hand side replaceable magazine 10a is now described. The C-frame 3 can be moved by the robotic arm 200 towards any of the two magazine carousels 37 in direction “h”. The C-frame is moved to the right to undock right-hand side magazine 10a until the corresponding pads 36a, 43a are in proximity one next to the other. In this configuration, magnetically correlated surfaces 39a on the magazines 10a is nearly magnetically engaged with corresponding correlated surface 44a on the attachment point 40a on the right hand side of the setting tool 2. The C-frame 3 may then undertake small movements in directions coplanar with the support pads 36a, 43a in directions “v” and “p” shown in
In the described arrangement it is the robotic arm 200 that moves the C-frame 3 and the setting tool 2 towards the magazine carousel 37 for undocking the magazine 10a. However, in principle, the carousel 37 could instead be moved toward the setting tool 2. Once undocked, the magazine 10a rests on previously spare support structure 41a in exactly the same way as other replacement magazines 10b, 10c, 10d rest on corresponding additional support structures 41b, 41c, 41d on the right hand side of the tool 2 as shown in
The same procedure can be applied to undock replaceable magazine 10e, so that it will then be supported on spare support structure 41e on the left-hand side carousel 37. This other carousel supports the three other replacement magazines 10f, 10g, 10h, as also shown in
By following a reverse sequence it is instead possible, for example, to dock one of the replacement magazines 10f, 10g, 10h on the left-hand side of the setting tool 2. For this purpose, assuming that replacement magazine 10f is chosen between the available replacement magazines 10f, 10g, 10h on the left-hand side of the setting tool, the magazine body 34f is first accommodated by moving the robotic arm and/or the carousel 37, as the case may be, within U-shaped portion 35f of the brackets 18 on the setting tool 2. Note that the left-hand side magazine carousel 37 shown in
The magnetic holding force that holds the replacement magazine 10f on the support 41f may be relatively high. Thus it may not be advisable to break the magnetic force between the magazine 10f and the support pad 43f by suddenly moving away the setting tool 2 in a predetermined direction as this could in principle damage the magazine 10f or the chute 16e (or both) as undue stress on the joint between the magazine 10f and the proximal end of the chute 17e may be generated. It may be possible first to perform small movements of the setting tool 2 in direction “p”, or in direction “v”, to bring the magazine pad 36f in slight misalignment with the support pad 43f on the support 41f. This may suitably weaken the magnetic bond between magnetically correlated surfaces 39f, 44f when the pads 36f, 43f are in perfect alignment, and this may in turn facilitate the release of the magazine 10f from the carousel 37. This feature can be enabled by the characteristics of the magnetic forces generated by the correlated-magnets on the replacement magazine 10f on one side and the support structure 41f on the other side. Replacement magazine 10f has now replaced replaceable magazine 10e on the left-hand side of setting tool 2.
Each magazine carousel 37 comprises four support structures 41, disposed in quadrant arrangement, one or more of which may be free to receive a replaceable magazine 10a, 10e as exemplified in
While any magazines 10 are supported on the carousels 37, refill can take place. Meanwhile, the loaded setting tool 2 is ready for new setting operations, until any of the replaceable magazines 10a, 10e will need to be replaced by any of the available replacement magazines 10b, 10c, 10d, 10f, 10g, 10h. In
The pairs of magnetically correlated surfaces 39, 44 provided, respectively, on the magazines 10 and on the supports 41 provided on the carousels 37 can be designed to facilitate the docking and undocking operations described above. For example, said pairs of magnetically correlated surfaces 39, 44 may provide for mechanical alignment of the respective pads 36, 44 in addition to magnetic holding. Alternatively or additionally, mechanical latching as described above could also be implemented. In addition, mechanical release could also be implemented, for example triggered by bringing the pads 36, 44 out of alignment further than a predetermined distance.
Further, the properties of the magnetically correlated surfaces 39, 44 could also in principle be used as a Poka-Yoke feature, that is to ensure that only predetermined magazines having appropriate magnetically correlated surfaces can be supported on any specific supports 41. This could be achieved, for example, by specifying a spring-type mechanical function between those magazines and any supports 41 not intended for that magazine. A coupling function can instead be specified between these magazines and the supports intended to support them on one of the carousels 37.
A process of refilling the replacement or replaceable magazines 10 is now described with reference to
While various docking mechanisms are possible, preferred methods involve providing the upper docking interfaces 12 of the magazines 10 with respective magnetically patterned surfaces 45 for connection and, more preferably, connection and alignment with, one or more corresponding magnetically correlated surfaces 46 provided on the lower docking interface 66 of the docking block 70 shown in
In the arrangement shown in
The rivet feed tubular member 49 is supported on a first support structure 53 which, in the shown arrangement, is in the form of a tripod 54 (only two arms of which are shown in the purely schematic representation of
The arrangement is such that when the magazine 10 hovers close to the correlated-magnets surface 46 provided on the refill device 48, the refill device 48 is gently drawn in contact with the docking interface 12 of the magazine 10, with the refill passageways 50 aligned with the two upper magazine tracks 60 in readiness for the magazine to receive rivets from the bulk feeder (not shown). This performance is made possible by the alignment function performed by the pair of correlated-magnets surfaces 45, 46 disposed, respectively, on the magazine docking interface 12 and on the lower docking interface 66 of the refill device 48 as shown in
When the refill operation is complete, as the refill device 48 is released (this can for example be determined by relative shear movement between the magazine 10 and the refill device 48), the compliant mounts 56, in cooperation with any additional springs provided for this purpose, return the rivet feed tubular member 49 to its default position shown in
The correlated magnets 65 may be mounted flush with the recessed mounting surface shown in
The arrangement in
Each vertical post 41 has features similar to the supports 41 described in connection with the magazine carousels 37 of
Magnetically patterned surfaces to aid with the docking of the magazines 10 could also be included in any one or more of the recess faces of the U-shaped portions 35 of the brackets set 18 on the setting tool 2. These recesses are clearly shown in
The arrangement shown in
In addition, the arrangement of
The utilisation of correlated-magnets surfaces in the procedures for refilling and/or replacing the magazines may conveniently reduce the positioning accuracy requirements on the robotic arm 200. Thus the robotic arm 200 may only be requested to dispose the magazines generally close to, for example, the refill device 48 of
With reference to
The pivotal arrangement of the magazines 10a, 10b is used to select supply of rivets from any one of the three independent magazine portions 11 of the rivet delivery tracks 8 on each side of the setting tool. For example, in the configuration shown in
The docking devices 114 are also represented in enlarged form in
At the distal end 20a of the magazine 10a, which is shown in more detail in
By rotating the magazine 10a around its pivot 81 (indicated in
With continued reference to
As mentioned above,
In
In
In
Selection of the required upper track 60 is performed by rotating rotary member 101 in one direction, or in the opposite direction, of about 145 degrees, as can be appreciated in particular referring to
Actuation of the track selection device 90 is via a pair of dedicated actuation lines 88, 89 as also shown in
The plate 121 is connected via a rod 122 to a piston actuator 123 disposed within a portion of the housing 97 of the linear-pin escapement 96 located below the magazine 10, as also visible in
With reference to
When the lead pin 120 is retracted as shown in
Possible options for the replacement and/or adjustment of the die assembly 6 are described briefly below in connection with
In
A method of ensuring that the correct die volume has been set may be advisable. This might be achieved by a combination of mechanical registration and/or software control. Thus for example only one of the multiple slots 131 of the spanner tool 130 may at any one time register together with the adjustment end 132 provided on the die assembly 6. The software may then determine the next required die volume 135 for the riveting process. The angular position of the adjustment end 132 will then need to be adjusted accordingly. When a successive die volume adjustment operation is required, the previous position of engagement between the spanner tool 130 and the adjustment end 132 of the die assembly 6 is recalled by the software from a memory. Alternatively/additionally, the spanner tool 130 could have slots 131 which are each associated with a specific die volume 135. Thus the robotic arm could be used to engage the adjustment end 132 of the die assembly 6 by any of these predetermined slots 131. A predetermined angular rotation could then also be associated to each slot. Therefore, upon engagement of the end 132 with a predetermined slot 131, a predetermined angular rotation would take place to achieve the desired die volume 135.
In
In
With reference to
When switching active cam platforms 143, the centre pin 140 may have to be retained in the position corresponding to its minimum die volume 135 to allow the adjustment cam mechanism 142 to be rotated.
With reference to
To replace the die 153, the protruding pin 157 is pushed upwardly by release pin 137 against the downwards force exerted on it by the resiliently biased sphere 158. This in turn releases the split collets 150 so that the die 153 is no longer gripped to die sleeve 141. The die 153 can be replaced with another die with different die volume 135 bay external means, including by manual intervention of an operator.
The invention thus provides a simple yet flexible magazine-based rivet supply system that can seamlessly handle self-piercing rivets of different shapes and sizes.
Any requirement for portions of flexible tubes within the rivet supply systems is reduced or eliminated.
The rivets are stored in magazines which are conveniently located at all times close to the nose of the setting tool.
Further, the magazines incorporate multiple rivet handling features which maximise control of the flow of the rivets through the supply system.
While the magazines described herein are preferably used with gravity or vacuum as the rivet motive force, these can also easily be adapted to accept compressed air, as it will be apparent to the skilled person.
The magazines can also be easily replaced and/or refilled, and these operations can further be conveniently carried out automatically by the robotic arm without the need for external intervention.
Further, the accuracy requirements relating to the robotic arm are advantageously reduced.
Further, it is possible, upon identification of a joint to be created, to call up a desired rivet type from one of the magazines docked on the setting tool, or from one or more replacement magazines, and, based on that selection, change or reconfigure the die assembly accordingly.
If a replacement magazine is required, the tool can prevent or signal inadvertent docking of an incorrect replacement magazine, and/or confirm that a correct replacement magazine that stores the intended rivets in terms of their type and/or size has been successfully selected and docked on the tool.
The invention has been described above purely by way of example. Protection is sought within the scope of the appended claims.
| Number | Date | Country | Kind |
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| 1720275 | Dec 2017 | GB | national |
| Filing Document | Filing Date | Country | Kind |
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| PCT/GB2018/053524 | 12/5/2018 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2019/110990 | 6/13/2019 | WO | A |
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| Number | Date | Country | |
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| 20200346277 A1 | Nov 2020 | US |
