Patent Application
20250135604
This disclosure relates generally to mechanical clamps.
Sheet metal parts are used in a multitude of applications and across many different industries (e.g., in aerospace, automotive, biomedical, and consumer electronics industries). Sheet metal part forming is the manufacturing process through which sheet metal parts are made. However, sheet metal part forming is very tool intensive, which makes it costly and time consuming to fabricate sheet metal parts. A method for sheet metal part forming is stamping. In stamping, a series of female and male dies that are specific to each design and material are fabricated (tooling). A sheet metal part is formed in a press machine by sandwiching sheet metal between the two dies with force. Stamping requires a large investment in dies and is not accommodating to changes in design and material, making the sheet metal forming process expensive and time-consuming.
Embodiments of the disclosure have other advantages and features which will be more readily apparent from the following detailed description and the appended claims, when taken in conjunction with the examples in the accompanying drawings, in which:
The Figures (FIGS.) and the following description relate to preferred embodiments by way of illustration only. It should be noted that from the following discussion, alternative embodiments of the structures and methods disclosed herein will be readily recognized as viable alternatives that may be employed without departing from the principles of what is claimed.
Reference will now be made in detail to several embodiments, examples of which are illustrated in the accompanying figures. The figures depict embodiments of the disclosed system (or method) for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles described herein.
Described are embodiments of a mechanical clamp or a clamping system. These clamps and clamping systems may be part of a system for robotic sheet forming as described herein.
A first example mechanical clamping system includes: a bottom clamp bar with holes and a top surface configured to interface with an object to be held; top clamp bars adjacent to each other and arranged along a portion of the bottom clamp bar, the top clamp bars having bottom surfaces configured to interface with the object to be held, the top clamp bars coupled with the bottom clamp bar through fastening members passing between respective holes of the top clamp bars and the holes of the bottom clamp bar; and pins coupled to bottom surfaces of the top clamp bars or top surfaces of the bottom clamp bar, the pins forming pivot points for bottom surfaces of the top clamp bars to pivot toward or away from the top surface of the bottom clamp bar.
A second example mechanical clamping system includes: a bottom clamp bar with a top surface configured to interface with an object to be held; a top clamp bar with a bottom surface configured to interface with the object to be held; a fastening member that passes through a first hole in the top clamp bar and a second hole in the bottom clamp bar; a pivoting receiving member coupled to a portion of the fastening member below the top surface of the bottom clamp bar; and a pivoting pin arranged below the top surface of the bottom clamp bar and engaged with a side of the pivoting receiving member to form a pivot point enabling the fastening member to pivot about the pivot point.
Robotic sheet part forming is a sheet metal part forming technique where a sheet is formed into a desired geometry by a series of incremental deformations applied by a robot. For example, the robot is outfitted with a stiff stylus that delivers deformations to the sheet. The robot may change tools to apply different operations (e.g., trimming and hemming) to the metal part. Multiple robots may be used in the process to provide more accurate control of the process.
Increasing the speed and decreasing the cost to manufacture sheet metal parts is desirable for enhancing product development in all stages of design and manufacturing. In light of this, some embodiments relate to an intelligent machine learning-based system that automates object process parameter generation for real-time control of novel robotic forming of sheet metal, plastics, polymers, and composite parts. Relative to conventional techniques, the disclosed (e.g., fast forming) techniques may enable faster prototyping and may enable rapid customization of mass-produced products. Agile production or prototyping in turn enables development of better-quality products and streamlining production. It may also increase industrial competitiveness in both mature and emerging markets by reducing the time and capital used for developing new components. The benefits may extend further for “lightweighting” strategies employed in various industries (e.g., aerospace and automotive) that want to move towards lighter and higher strength alloys but are slowed down by testing of these alloys. For simplicity, the below descriptions refer to forming parts from sheet metal. However, as indicated above, embodiments described herein may be applicable to forming parts from other materials, such as plastics, polymers, and composites.
Robotic sheet metal part forming overcomes the restrictions of the traditional methods by reducing or removing fabrication of tooling and dies from the production process. Robotic sheet part forming is a sheet metal part forming technique where a sheet is formed into a desired geometry by a series of (e.g. small) incremental deformations applied by a robot. For example, the robot is outfitted with a stiff stylus that delivers deformations to the sheet. Multiple robots may be used in the process to provide more accurate control of the deformations.
The use of two robots (one on each side of the sheet) may provide several advantages. For example, if only a single robot is used, the sheet may globally deform (instead of locally deform). Thus, using two robots may enable localized deformations. A second robot (also referred to as a support robot) may reduce or prevent tearing of the part by providing supporting pressure on the opposite side of the part. The location of the robots (and their end effectors) with respect to each other may be based on the design of the part and the material and thickness of the sheet. These locations may be determined by a model (described further below). An example of the advantages of two robots is illustrated in
A controller may receive and process sensor data from the sensors to determine the proper parameters (e.g., joint angle values for each joint of the robotic arm) and control the robot arms accordingly. In some embodiments, the robots are controlled to pinch or otherwise apply pressure to the sheet metal with a hard implement (e.g., a stylus) or other tool to form the sheet of metal in accordance with a program applied by the controller to result in a desired geometry. For example, the program controls the robot arms to move in a particular sequence and apply the tool to the sheet metal according to particular programmed parameters at each step (e.g., time step) of the sequence to achieve a programmed geometry. The program (via the robotic arms) may cause the different applied tools to bend, pinch, cut, heat, seam, or otherwise form the metal in accordance with the program.
An example part forming process is illustrated in
The controller determines the process parameters to achieve the desired robotic forming operations. Parameters such as the path of the robotic forming tool during the process, its speed, geometry of the forming tool, amount of force, angle and direction of the forming tool, clamping forces of the sheet, etc. may have direct but nonlinear effects on the final geometry. The part forming process may include a set of time steps, where each step describes parameters values for one or more parameters. The part forming process may be iterative. Thus, by executing the system according to the parameter values at each time step, the controller may form the part described in the input design. The parameters values may be determined by the model.
The disclosed robotic system may achieve real-time adaptive control of a part forming process. The method may start with an input design of a part and a (e.g., statistical) model that is generated using a training data set. The training data set may include data from simulation data, and physical process characterization data (such as an in-process inspection or post-build inspection from previously formed parts or geometries). An in-process inspection may include inspecting a part during the forming process. For example, a scanning sensor records the shape of the part as it is being formed. In another example, an eddy current sensor detects defects like cracks. In another example, a force sensor measures the forces applied to the part. A post-build inspection is intended to gather information on a fully formed part. A post-build inspection may include similar inspection techniques as an in-process inspection (e.g., inspecting a part using a scanning sensor or eddy current sensor). However, a post-build inspection may include inspection techniques not performed while the part is being formed (e.g., due to practicality). For example, a fully formed part may be inspected using an x-ray machine.
A state of the part may be described by a mesh. The mesh may be a graph of coupled nodes, where each node represents a physical point of the part metal. Each node may be described by the following variables: X, Y, Z, F1z, F1x, Fly, F2z, F2x, F2y, thickness, dx, dy, and dz. X, Y, and Z represent the location of the node in space. Thickness indicates the sheet thickness at that node. Each node may be coupled to neighboring nodes (e.g., three neighbors). These coupled nodes represent the part in cartesian space. F1z, F1x, and Fly represent the force that one of the robots (e.g., robot 1) is applying at that node, and F2z, F2x, F2y represent the force another robot (e.g., robot 2) is applying at that node. dx, dy, and dz represent the size of movements capable at a node if the robots pull back from the part at this time (e.g., they capture the elastic strain of the material).
The model can be used to determine the process parameters (e.g., in real time or offline). This method automates the generation of parameters for the robotic forming process (further described in the next paragraph). Due to the optimization process, the generated parameters may not be conceivable by engineers.
After the model is determined (e.g., by a training process), optimization techniques may be used to determine parameters to apply at each (e.g., time) step of the part forming process to create the intended part geometry. For example, for a given time step, the model is applied to various input parameter values according to an optimization technique to determine which parameter values will result in a desired geometry (or a geometry close to the desired geometry). Multiple optimization techniques may be used. Example optimization techniques include gradient descent, Adam optimization, and Bayesian optimization. An optimization technique may be chosen based on the complexity of the desired geometry. The optimization may be done both in the long and short horizons (e.g., time scales). The long horizon optimization may be done offline (before the part forming process begins) to determine steps of the process (e.g., step by step instructions for the robot to achieve the desired geometry). For example, a long horizon optimization may determine how to form a material sheet into a fully formed part. In some embodiments, long horizon optimizations determine a set of intermediate geometries that occur during a part forming process (e.g., intermediate geometries between the sheet and the fully formed part (e.g., for each time step or layer)). However, errors or inaccuracies may accrue over time (e.g., for processes with lengthy build times or processes with a large number of time steps). For example, the part may deform differently than the model predicted. To remedy this issue, short horizon optimizations may be performed during the forming process (online) to reduce or correct errors that may accrue. For example, the model is queried by a (e.g., online) controller that can modify (e.g., correct) steps determined during the long horizon optimization based on the current state of the sheet. For example, for a given time step, instead of assuming the part has a geometry predicted by the long horizon optimization, sensor data may be used to determine the actual geometry of the part. The model may then be queried to determine a new set of parameter values for the time step (or modify the long horizon parameters associated with the time step). For example, the model may be queried to determine which parameter values will form the actual geometry into the predicted geometry (or another intermediate geometry from the long horizon optimization).
While long horizon optimizations may be used to determine an entire part forming process or significant portions of the process, determinations made by short horizon optimizations may be limited to small portions of the part forming process. For example, a short horizon optimization determines a number of interactions (e.g., less than ten) between the end effector and the part. In another example, a short horizon optimization determines interactions between the end effector and the part that will occur during a time window (e.g., less than ten seconds). In another example, a short horizon optimization determines parameter values for a set of time steps (e.g., less than ten time steps). In another example, a short horizon optimization determines how to form a part in a first geometry into a second geometry, where the first and second geometries are intermediate geometries determined by a long horizon optimization. In another example, a short horizon optimization is used to determine how to form a part so that it is a threshold percent closer to a final geometry (e.g., less than ten percent).
In some embodiments, a long horizon optimization is used without short horizon optimizations (e.g., the model has a threshold accuracy or the part forming process has a short build time or a small number of time steps). In some embodiments, short horizon optimizations are used without a long horizon optimization.
Referring back to the model 200, the model may be trained using the data from a simulation module. Additionally, or alternatively, the model 200 may be trained using data (e.g., sensor data) from a physical process that forms a part.
In some embodiments, multiple models are trained. For example, models may be trained using different machine learning techniques. Additionally, or alternatively, models may be trained for specific materials (e.g., steel vs. aluminum), geometries (simple vs. complex), or sheet thickness (e.g., 1 mm vs. 2 mm). Among other advantages, models trained for specific specifications may be more accurate than a general model.
The model 200 may also be applied by the controller 255 of the robotic system 260 in the online process. More specifically, the model 200 may determine predictions about the resulting change in geometry from each parameter change at each point in time in the part forming process. In the online process, the controller uses sensors installed on the robotic forming system to obtain sensor data 265 to determine a current geometry of the part. The current geometry may then be input to the model 200. The model predicts the outcome (e.g., a resulting change in geometry) of changes in those process parameters. By iterating over different possible parameters and their outcome predicted by the model, the controller identifies and chooses the (e.g., best) parameter 250 that produces the most desirable outcome to control the robotic forming system through a forming process that achieves the desired geometry. The controller uses the best parameters and may repeats this optimization cycle (e.g., in every step of the process) to improve the outcome.
In addition to the model 200 described above with respect to
A more complex model is the one that breaks the forming process into layers and tries to predict the effect of various parameter values at each layer. In this context, “layer” refers to a section of a part. For example, a first layer refers to the section that extends one inch away from the original sheet and a second layer refers to the section that extends from the first inch to the second inch. An example of a layer based model is further described below.
Model 1415 may be developed as a sequence model which means it may be any of the sequence architectures (e.g., RNN, LSTM, Transformers). This model has more advantages than model 1400 since it is agnostic to general changes to the policy for forming robots. For example, model 1415 may be used to model inset adding or doing ADSIF or grouped DSIF. That being said, in some embodiments, model 1415 does not capture physical phenomena that may occur during each layer or group of layers.
Referring back to
Referring back to
By varying different input process parameters such as the forming path, its speed, and the geometry being formed, the simulation module 225 can generate a (e.g., large) data set indicating how a specific metal is deformed with this process (e.g., how metal deforms in response to certain input parameters). The simulation data is used to train a model (e.g., by a training module). The model may be trained using one or more different machine learning techniques and constructs, such as Neural Networks, Random Forests, Decision trees, or regressions. in some embodiments, the training techniques are supervised learning techniques.
In some embodiments, the simulation data is used to train an initial model. The initial model may then be refined or retrained using data from physical part forming processes to increase the accuracy of the model.
In the examples described above, the model is generally described in the context of forming operations. However, the model (or another model) may be trained to predict other part operations, such as trimming or hemming.
The model created using simulation data may be further trained from data derived from an actual physical process that uses a robot arm and an actual sheet. The physical system is equipped with one or more different types of sensors. Example sensors include: (1) encoders in the robot joints that provide positional information as determined by the position of the joints, (2) optical trackers (e.g., a camera) that track the location of robot in (e.g., 3D) space, (3) surface scanners to generate as-built geometry of the part before, during, and after the forming process (surface scanners may have a point accuracy of 0.5 mm), (4) load sensors that determine the force the forming end effectors apply on the sheet, (5) ultrasonic sensors (e.g., electromagnetic acoustic transducer or EMAT) for real-time monitoring of material thickness, and (6) eddy current sensors (e.g., pulsed eddy current) for real-time monitoring of the metallurgical state of metallic sheet. In some embodiments, if the surface scanner is attached to the robot arm, surface scanner data may be stitched together based on the encoder data to determine the geometry of a part (the location of the scanner depends on the position of the arm).
The encoders may be attached to each joint on the robot to track its actual movement, the optical trackers may be mounted around the manufacturing cell. This allows the optical trackers to capture images that include tracking targets installed on the robotic arms and the frame holding the sheet in place. The load sensor and scanner may be attached to the end-of-arm tooling to track forming forces and deformation of the sheet during the process.
Example optical trackers are illustrated in
In some embodiments, the robot arm is outfitted with a scanner and a load sensor (e.g., force/torque sensor) as illustrated in
With the sensors described above, accurate data can be captured to characterize steps of a part forming process.
Referring back to
Once a process model 200 is generated using the above-described training process, the model may be applied in the control process of the robotic forming in two ways. The model may as an input takes a specification for a sheet, such as its material properties (e.g., stress-strain curve) and failure criteria. It may also receive a specification for forming paths (which may initially be determined offline) and the type and size of the tool. The model can be either queried online for optimized process parameters for each time step of the process in real-time, or it can be used in the design of experiments offline to determine optimal policy for forming the part. The policy here refers to general pathing strategies in forming a part.
Two categories of systems discussed below may increase the speed of sheet metal part fabrication using robots. The first system and design (“Forming With Rollers”) increases the speed of the forming process itself, while the second (“Integration of Downstream Processes”) addresses downstream processes from part forming to decrease total fabrication time.
6. Forming with Rollers
To increase the speed of the part forming process, an end-effector tool may be configured to interact with the sheet metal with reduced (e.g., low) friction forces. Reducing friction allows for reduction in vibrations in the sheet and hence allows increased speed of forming without negative impact on the geometrical accuracy of the formed part. It may also result in better surface quality (e.g., reduced tearing and galling) compared to tools not configured to reduce friction (e.g., static forming tools).
An example tool configured to reduce friction is a stylus made of a material (or coated with a material) configured to reduce friction. Thus, if the stylus is dragged across the surface of a part, the reduced friction may reduce or eliminate surface degradations and increase the path speed.
Other tools configured to reduce friction may include roller tools. Roller tools may result in lower friction forces than a stylus. Different rollers with different radii and shape can be used to accommodate for different features in the part design.
In some embodiments, the roller can only roller about a single rotational axis (e.g., as in
In some embodiments, a roller tool includes a roller that can rotate about multiple rotational axes. An example, of this is illustrated in
The disclosed roller design installed on a robotic setup allows for robotic part forming with reduceds friction, hence reduced forces which then allows for better surface quality of the formed part and increased speed of the forming process.
Sheet metal part forming may be one of many manufacturing steps performed to produce a final sheet metal part. For example, a sheet metal part also goes through trimming, hole making, hemming, or other processing steps after the part forming process. Traditional methods involve transferring a sheet metal part from one specialized manufacturing station to another, performing each manufacturing step in each corresponding station to produce the delivering the final part. This results in increased manufacturing time due to the time for physically moving the part from one station to another.
Each of the downstream processes generally has its own specific tooling. For example, for trimming a part, it is desirable to use a geometry specific frame that can hold the geometry of the part while a trimming operation is performed.
In some embodiments, the robotic system allows for performing two or more (e.g., all) downstream manufacturing steps in the same station using the same robotic setup, thus avoiding moving of the part and decreasing the total fabrication time. Each downstream process may use a different tool. For example, when performing trimming (e.g., hole making), the robot arm may attach different tools such as a spindle, laser, or a plasma torch. The robotic arm can be controlled to automatically change the tool through software instructions of the program executed by the controller (e.g., controller 255). For example, the controller can control the robot arm at varying times throughout the process to perform a programmed operation on the sheet metal with a particular tool, to control an actuator to release a tool from the tool holder (e.g., into a tool rack), and to cause the robot arm to attach a new tool from the tool holder (e.g., from the tool rack) for performing a subsequent operation.
In some embodiments, the steps that enable automatic integration of downstream processes in the same station may include the following. (1) the robot goes to a tool rack and picks up a forming tool (e.g., a stylus) using predefined software instructions sent to the robot. (2) the robot forms a part from a flat sheet of metal through software defined path and parameters. (3) After the part is formed, the robot moves back to the tool rack, disengages (e.g., drops) the forming tool, and picks up a trimming tool. This step may also be automated with software instructions. (4) The robot performs a trimming operation on the part with the trimming tool. If further downstream processes, such as hemming (e.g., bending), are used to finish the part, the system may continue from step 3 until no more processes are left to perform. If a station includes multiple robots, the robots may work in conjunction using the same or different tools to achieve a desired process (e.g., a forming or trimming process).
If a manufacturing area includes multiple cells (e.g., each including two robot arms), instead of each cell changing tools to perform different operations, each cell may be assigned to a specific operation. In these embodiments, a part may be moved from one cell to another after each operation on the part is complete.
Thus, the stand design and software-controlled tool changer for controlling the robotic arms allows for automated downstream operations from forming of the sheet metal parts such as trimming, bending, and hemming without removing the part from the fixture and requiring geometry specific fixture.
Furthermore, additional, or fewer horizontal or vertical bars can be attached to frame 1600. Furthermore, the vertical and/or horizontal bars may be manufactured in a variety of sizes (e.g., lengths) to accommodate different sized objects. In some embodiments, clamps integrated along edges of frame 1600 (e.g., 1601) are the same clamps as those of the horizontal bar of clamps 1605 and/or the vertical bar of clamps 1610.
A horizontal bar of clamps (e.g., 1605) may be referred to as a horizontal clamping system. A vertical bar of clamps (e.g., 1610) may be referred to as a vertical clamping system. Horizontal clamping systems and vertical clamping systems are further described below. The terms “horizontal” and “vertical” are relative terms used for convenience. For example, a horizontal clamping is not required to be arranged horizontally. Similarly, a vertical clamping system is not require to be arranged vertically. Furthermore, although horizontal and vertical clamping systems are described below as having different components and features, a horizontal clamping system may have components and/or features described with respect to the vertical clamping features and vice versa. For example, the clamp described with respect to
Furthermore, components of clamping systems are described below using relative terms such as “top,” “bottom,” “side,” “below,” and “above.” These terms and similar terms are used for convenience to describe the position of one component relative to another component. These terms and similar terms do not describe a required orientation. For example, depending on the orientation of a clamping system, a “top clamp bar” may be below or next to a “bottom clamp bar.” In another example, depending on the orientation of a clamping system, a “top surface” of a component may face downward or in a lateral direction relative to the ground.
Horizontal clamping system 1700 includes a set of seven clamps adjacent to each other (other embodiments may include additional or fewer clamps), and each of the seven clamps include the same parts (other embodiments may include clamps with different parts). Each of the seven clamps may open or close about by rotating about the same axis, which is parallel to the x-axis (e.g., each of the clamps rotate about pivot points that are aligned with each other). However, for convenience,
Clamp 1701 includes top clamp bar 1703, bottom clamp bar 1705, and screw 1707. Screw 1707 is a structure passes through hole 1727 in top clamp bar 1703 and hole 1728 in bottom clamp bar 1705. Note that a clamp (e.g., 1701) is not limited to use of a screw (e.g., 1707). More generally, a clamp may include a fastening member, such as a threaded fastening member (example threaded fastening members include a screw, a threaded rod, and a bolt). Clamp 1701 can be closed by screwing screw 1707 into hole 1728 (which results in top clamp bar 1703 moving closer to bottom clamp bar 1705) and opened by unscrewing screw 1707 from hole 1728 (which results in top clamp bar 1703 moving farther from bottom clamp bar 1705). More specifically, as clamp 1701 is closed, top clamp bar 1703 tilts forward toward bottom clamp bar 1705 as the top portion of screw 1707 translates toward bottom clamp bar 1705 (an example closed clamp position is illustrated in
In the perspective of
In the example of
As previously described, screw 1707 passes through hole 1727 in top clamp bar 1703 and hole 1728 in bottom clamp bar 1705. Hole 1727 may be larger than the diameter of screw 1707 enough to allow top clamp bar 1703 to pivot (e.g., by zero to five, ten, fifteen, or twenty degrees) relative to screw 1707 (and bottom clamp bar 1705), which increases the clearance for loading and unloading an object in the clamp. For example, hole 1727 has an oblong shape (e.g., hole 1727 is a slot) with the long axis being in the rotation direction of top clamp bar 1703 about the pivot point as further described below (said differently, the long axis is perpendicular to the rotational axis).
Pivot pin 1717 is a cylindrical pin (however other pin shapes are possible). In the perspective of
Top clamp bar 1703 (or bottom clamp bar 1705) may include a pin indent 1721 (also referred to as a recess) configured to receive at least a portion of pivot pin 1711, which may help installation of pivot pin 1711 and may help hold pivot pin 1711 in place during operation (e.g., in addition to any other fastening mechanisms, such as screws).
During opening or closing of clamp 1701, the top of screw 1707 can translate relative to bottom clamp bar 1705 (by being screwed or unscrewed). Clamp 1701 may include retaining ring 1731 coupled to a portion of screw 1707 between the interface surfaces of top clamp bar 1703 and bottom clamp bar 1705. Retaining ring 1731 may remain coupled to the same portion of screw 1707, even when screw 1707 translates. Thus, in the perspective of
In the perspective of
Among other advantages, clamp 1701 enables top clamp bar 1703 and screw 1707 (as well as washer 1737, retaining ring 1731, and pivot pin 1717) to be removed from clamp 1701 by unscrewing screw 1707 past a threshold (e.g., unscrewing screw 1707 out of bottom clamp bar 1705). For example, removal of these components may make installation of horizontal clamping system 1700 on a frame easier and lighter. Furthermore, removal of these components may make it easier to place an object to be held on bottom clamp bar 1705 (and the components may be added back afterwards). Furthermore, if these components are removed (e.g., for all clamps on horizontal clamping system 1700), horizontal clamping system 1700 to be used as a support beam. For example, horizontal clamping system 1700 can be placed behind an object held in a frame (held by other clamps) to support the object and/or reduce or eliminate bending or flexing of the object (e.g., during part forming operations).
In some embodiments, a clamp (e.g., 1701) includes teeth to increase the hold of the object. For example, clamp 1701 includes serrated teeth 1729. Teeth 1729 may be a ˜1 millimeter insert and may be installed in a recess in bottom clamp bar 1705 (recess is not labeled in
Vertical clamping system 1700 includes coupling elements 1741A and 1741B on sides of bottom clamp bar 1705. Coupling elements 1741A, 1741B enable horizontal clamping system 1700 to be coupled to (e.g., mounted to) a frame or another horizontal or vertical clamping system (e.g., via bolts or screws).
Additional example embodiments of clamping systems are described below. Although references are made to vertical clamping system 1700 in the below descriptions, the example embodiments described below are not required to include the components or features previously described with respect to vertical clamping system 1700.
Some aspects relate to a mechanical clamping system (e.g., horizontal clamping system 1700) configured to hold a side of a sheet of material (e.g., 110, 520, 700, 910, 1015) in a frame (e.g., 115, 915, 1600), the mechanical clamping system including: a bottom clamp bar (e.g., bottom clamp bar 1705) with a top surface configured to interface with the sheet to be held; top clamp bars (e.g., including top clamp bar 1703) adjacent to each other and arranged along a portion of the bottom clamp bar, the top clamp bars having bottom surfaces configured to interface with the sheet to be held; screws (e.g., including screw 1707) that pass through holes in the top clamp bars (e.g., including hole 1735) and holes in the bottom clamp bar (e.g., including hole 1727) (a screw may have a long dimension that is parallel to the z-axis as illustrated in
In some aspects, the mechanical clamping system further includes retaining rings (e.g., including retaining ring 1731) coupled to portions of the screws between the top surface of the bottom clamp bar and the bottom surfaces of the top clamp bars.
In some aspects, the retaining rings are positioned on the screws to push the bottom surfaces of the top clamp bars to pivot away from the top surface of the bottom clamp bar responsive to the screws being moved upward (e.g., unscrewed for example from the bottom clamp bar and/or moved along the +z-axis as indicated in
In some aspects, the top clamp bars include rounded edges (e.g., including rounded edge 1733) configured to interface with sheets that have a range of thicknesses.
In some aspects, pivot axes of the pivot points are parallel to each other (e.g., see
In some aspects, the techniques described herein relate to a mechanical clamping system, wherein pivot axes of the pivot points are aligned with each other (e.g., see
In some aspects, the holes in the top clamp bars are oblong in directions perpendicular to pivot axes of the pivot points (e.g., see
In some aspects, the mechanical clamping system further includes: washers (e.g., including washer 1737) on portions of the screws above the bottom surfaces of the top clamp bars, the washers including rounded surfaces facing the top clamp bars (e.g., see
In some aspects, top surfaces of the top clamp bars include indentations (e.g., including indent 1739) shaped to receive (e.g., to match) the rounded surfaces of the washers (e.g., see
In some aspects, the mechanical clamping system further includes coupling elements (e.g., coupling element 1741A and coupling element 1741B) coupled to opposite ends of the mechanical clamping system (e.g., the bottom clamp bar). The coupling elements are configured to mount the bottom clamp bar to the frame.
Other aspects include components, devices, systems, improvements, methods, processes, applications, computer readable mediums, and other technologies related to any of the above.
Vertical clamping system 1800 includes a set of fourteen clamps, and each of the clamps include the same parts (other embodiments can include additional or fewer clamps and different clamps may include different parts). However, for convenience,
Clamp 1801 includes top clamp bar 1803, bottom clamp bar 1805, and screw 1807. Screw 1807 is a structure that passes through hole 1827 in top clamp bar 1803 and hole 1828 in bottom clamp bar 1805. Note that a clamp (e.g., 1801) is not limited to use of a screw (e.g., 1807). More generally, a clamp may include a fastening member, such as a threaded fastening member (example threaded fastening members include a screw, a threaded rod, and a bolt). Clamp 1801 can be closed by screwing screw 1807 (which results in top clamp bar 1803 moving closer to bottom clamp bar 1805) and opened by unscrewing screw 1807 (which results in top clamp bar 1803 moving farther from bottom clamp bar 1805). Pivot nut 1809 may include threads that receive threads of screw 1807.
More specifically, as clamp 1801 is closed, top clamp bar 1803 and the top portion of screw 1807 tilt forward toward bottom clamp bar 1805 in addition to top clamp bar 1803 and the top portion of screw 1807 translating toward from bottom clamp bar 1805 (an example closed clamp position is illustrated in
Top clamp bar 1803 (and the top portion of screw 1807) may rotate enough (or sufficiently) for an object to be placed in the clamp by traveling along the clamp direction. For example, in the view of
In the perspective of
In the example of
Clamp 1801 includes pivot nut 1809, however note that a clamp (e.g., 1801) is not limited to use of a nut (e.g., 1809). More generally, a clamp may include a (e.g., threaded) receiving member for a (e.g., threaded) fastening member (e.g., 1807). Pivot nut 1809 is coupled to a portion of screw 1807 below bottom clamp bar 1805 (e.g., below the clamping interface of bottom clamp bar 1805). The exterior surface of pivot nut 1809 facing bottom clamp bar 1805 has a rounded shape, such as a cylindrical shape or a barrel shape. Bottom clamp bar 1805 may include indent 1825 (also referred to as a socket or recess) shaped to receive a portion of pivot nut 1809, which helps pivot nut 1809 rotate about an axis parallel to the y-axis. For example, indent 1825 includes a rounded surface that receives the rounded exterior surface of pivot nut 1809.
As previously described, pivot nut 1809 is coupled to a portion of screw 1807 below bottom clamp bar 1805. During opening or closing of clamp 1801, screw 1807 translates relative to pivot nut 1809. An end nut 1847 is coupled to the end of screw 1807 and configured to prevent screw 1807 from being further unscrewed when end nut 1847 contacts pivot nut 1809. Thus, end nut 1847 restricts movement of screw 1807 (e.g., compare the position of end nut 1847 relative to pivot nut 1809 in
Clamp 1801 includes pivot pin 1811. Pivot pin 1811 is a cylindrical pin arranged to engage with a side of pivot nut 1809 (however other pin shapes are possible). Pivot pin 1811 may help hold pivot nut 1809 in place near the bottom clamp bar 1805 (e.g., in indent 1825), while allowing pivot nut 1809 to rotate about an axis parallel to the y-axis. Thus pivot pin 1811 engaged with pivot nut 1809 may form a “first” pivot point which allows screw 1807 (and top clamp bar 1803) to tilt forward when clamp 1801 is closed and tilt backward when clamp 1801 is opened. In the example of
In some embodiments, bottom clamp bar 1805 includes pin indent 1819 (also referred to as a recess) configured to receive at least a portion of pivot pin 1811, which may help installation of pivot pin 1811 and may help hold pivot pin 1811 in place during operation (e.g., in addition to any other fastening mechanisms, such as screws). In the example of
As previously described, screw 1807 passes through hole 1827 in top clamp bar 1803 and hole 1828 in bottom clamp bar 1805. Hole 1828 may be large enough to allow screw 1807 to tilt (e.g., when clamp 1801 is opened or closed during operation), which increases the clearance for loading and unloading an object in the clamp. For example, hole 1828 has an oblong shape (e.g., hole 1828 is a slot), with the long axis being in the rotation direction of screw 1807 about the first pivot point. Similarly, hole 1827 may be large enough to allow top clamp bar 1803 to pivot (e.g., by a few degrees) relative to screw 1807 (and bottom clamp bar 1805), which also increases the clearance for loading and unloading an object in the clamp For example, hole 1827 has an oblong shape (e.g., hole 1827 is a slot) with the long axis being in the rotation direction of screw 1807 about the first pivot point (or in the rotation direction of top clamp bar 1803 about the second pivot point as further described below).
Pivot pin 1817 is a cylindrical pin (however other pin shapes are possible). In the perspective of
In the perspective of
Top clamp bar 1803 (or bottom clamp bar 1805) may include a pin indent 1821 (also referred to as a recess) configured to receive at least a portion of pivot pin 1811, which may help installation of pivot pin 1811 and may help hold pivot pin 1811 in place during operation (e.g., in addition to any other fastening mechanisms, such as screws).
In the perspective of
As previously described, screw 1807 (and top clamp bar 1803) can rotate about the first pivot point as clamp 1801 is opened (e.g., by unscrewing screw 1807). This rotation may be due to spring 1823 applying a force to rotate screw 1807. Spring 1823 is coupled to ends of shoulder screw 1830 and shoulder screw 1831. Spring 1823 applies a force to bring the ends of the shoulder screws together. Shoulder screw 1830 is coupled to and extends away from a back side of top clamp bar 1803 (e.g., see
In some embodiments, a clamp (e.g., 1801) includes teeth to increase the hold of the object. For example, clamp 1801 includes serrated teeth 1829. Teeth 1829 may be a ˜1 millimeter insert and may be installed in a recess in bottom clamp bar 1805 (recess is not labeled in
Vertical clamping system 1800 includes coupling elements 1841A and 1841B on sides of bottom clamp bar 1805. Coupling elements 1841A, 1841B enable vertical clamping system 1800 to be coupled to (e.g., mounted to) a frame or another horizontal or vertical clamping system (e.g., via bolts or screws).
Additional example embodiments of clamping systems are described below. Although references are made to vertical clamping system 1800 in the below descriptions, the example embodiments described below are not required to include the components or features previously described with respect to vertical clamping system 1800.
Some aspects relate to a mechanical clamping system (e.g., vertical clamping system 1800) configured to hold an object (e.g., 110, 520, 700, 910, 1015), the mechanical clamping system including: a bottom clamp bar (e.g., bottom clamp bar 1805) with a top surface configured to interface with the object to be held; a top clamp bar (e.g., top clamp bar 1803) with a bottom surface configured to interface with the object to be held; a screw (e.g., screw 1807) that passes through a first hole (e.g., hole 1827) in the top clamp bar and a second hole (e.g., hole 1828) in the bottom clamp bar; a pivoting nut (e.g., pivot nut 1809) coupled to a portion of the screw below the top surface of the bottom clamp bar; and a pivoting pin (e.g., pivot pin 1811) arranged below the top surface of the bottom clamp bar and engaged with a side of the pivoting nut to form a pivot point enabling the screw to pivot about the pivot point.
In some aspects, the pivoting nut includes a curved wall (e.g., wall 1813) and an end of the pivoting pin engages with the curved wall to form the pivot point.
In some aspects, a surface of the pivoting nut includes an indentation (e.g., indent 1815) and an end of the pivoting pin engages with the indentation to form the pivot point. For example, the end of the pivoting pin rests in the indentation and the pivot point is formed by the end of the pivoting pin contacting a side of the indentation.
In some aspects, the pivoting pin is coupled to a bottom surface of the bottom clamp bar (e.g., see
In some aspects, the pivoting pin (e.g., pivot pin 1811) at least partially rests in an indentation (e.g., pin indent 1819) of the bottom surface of the bottom clamp bar.
In some aspects, a bottom surface of the bottom clamp bar includes an indentation (e.g., indent 1825) shaped to receive at least a portion of the pivoting nut. Due to this, the pivoting nut can rest in the indentation. The indentation may have a cylindrical or barrel shaped recess to receive (e.g., to match) the exterior surface of the pivoting nut (e.g., in embodiments where the pivoting nut has a cylindrical or barrel-shaped exterior surface shape).
In some aspects, the top clamp bar includes a rounded edge (e.g., rounded edge 1733) configured to interface with the object to be held. Among other advantages, the rounded edge enables the mechanical clamping system to hold objects of different thicknesses.
In some aspects, the mechanical clamping system further includes a second pivot pin (e.g., pivot pin 1817) coupled to a rear portion of the bottom surface of the top clamp bar, the second pivot pin configured to (e.g., when in contact with the top surface of the bottom clamp bar) form a second pivot point for the top clamp bar (e.g., see
In some aspects, the bottom surface of the top clamp bar includes an indentation (e.g., pin indent 1819) shaped to receive at least a portion of the second pivot pin (e.g., pivot pin 1817). Due to this, the second pivot pin can rest in the indentation. The indentation may have a cylindrical shaped recess to receive (e.g., to match) the exterior surface of the second pivot pin (e.g., in embodiments where the second pivot pin has a cylindrical exterior surface shape).
In some aspects, the mechanical clamping system, further includes a spring (e.g., spring 1823) coupled to the top clamp bar and the bottom clamp bar, the spring applying a force to rotate the screw about the pivot point (e.g., pivot point formed by pivot pin 1811 and/or pivot point formed by pivot pin 1817). The spring is applying a force to move the top clam bar 1803 into an open position. In the example of
In some embodiments, a first end of the spring is coupled to a first shoulder screw which is coupled to and protruding from a backside of the top clamp bar, and a second end of the spring is coupled to a second shoulder screw that is coupled to the bottom clamp bar (e.g., directly coupled to the bottom clamp bar or coupled to a rear wall which is coupled to the bottom clamp bar (e.g., see
Other aspects include components, devices, systems, improvements, methods, processes, applications, computer readable mediums, and other technologies related to any of the above.
In some embodiments, the controller (e.g., controller 255 or controller 1120) is a machine able to read instructions from a machine-readable medium and execute them in a set of one or more processors.
The machine may be a server computer, a client computer, a personal computer (PC), a tablet PC, a smartphone, an internet of things (IoT) appliance, a network router, or any machine capable of executing instructions 1524 (sequential or otherwise) that specify actions to be taken by that machine. Further, while only a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines that individually or jointly execute instructions 1524 to perform any one or more of the methodologies discussed herein.
The example computer system 1500 includes a set of one or more processing units 1502. The processor set 1502 is, for example, one or more central processing units (CPUs), one or more graphics processing units (GPUs), one or more digital signal processors (DSPs), one or more state machines, one or more application specific integrated circuits (ASICs), one or more radio-frequency integrated circuits (RFICs), or any combination of these. If the processor set 1502 include multiple processors, the processors may operate individually or collectively. The processor set 1502 also may be a controller. The controller may include a non-transitory computer readable storage medium that may store program code to operate (or control) the robots, e.g., 400A, 400B, and/or other automated components described herein.
For convenience, the processor 1502 is referred to as a single entity but it should be understood that the corresponding functionality may be distributed among multiple processors using various ways, including using multi-core processors, assigning certain operations to specialized processors (e.g., graphics processing units), and dividing operations across a distributed computing environment. Any reference to a processor 1502 should be construed to include such architectures.
The computer system 1500 also includes a main memory 1504. The computer system may include a storage unit 1516. The processor 1502, memory 1504 and the storage unit 1516 communicate via a bus 1508.
In addition, the computer system 1500 can include a static memory 1506, a display driver 1510 (e.g., to drive a plasma display panel (PDP), a liquid crystal display (LCD), or a projector). The computer system 1500 may also include alphanumeric input device 1512 (e.g., a keyboard), a cursor control device 1514 (e.g., a mouse, a trackball, a joystick, a motion sensor, or other pointing instrument), a signal generation device 1518 (e.g., a speaker), and a network interface device 1520, which also are configured to communicate via the bus 1508.
The storage unit 1516 includes a machine-readable medium 1522 on which is stored instructions 1524 (e.g., software) embodying any one or more of the methodologies or functions described herein. The instructions 1524 may also reside, completely or at least partially, within the main memory 1504 or within the processor 1502 (e.g., within a processor's cache memory) during execution thereof by the computer system 1500, the main memory 1504 and the processor 1502 also constituting machine-readable media. The instructions 1524 may be transmitted or received over a network 1526 via the network interface device 1520.
While machine-readable medium 1522 is shown in an example embodiment to be a single medium, the term “machine-readable medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, or associated caches and servers) able to store the instructions 1524. The term “machine-readable medium” shall also be taken to include any medium that is capable of storing instructions 1524 for execution by the machine and that cause the machine to perform any one or more of the methodologies disclosed herein. The term “machine-readable medium” includes, but not be limited to, data repositories in the form of solid-state memories, optical media, and magnetic media.
While machine-readable medium 722 (also referred to as a computer-readable storage medium) is shown in an embodiment to be a single medium, the term “machine-readable medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, or associated caches and servers) able to store the instructions 724. The term “machine-readable medium” shall also be taken to include any medium that is capable of storing instructions 724 for execution by the machine and that cause the machine to perform any one or more of the methodologies disclosed herein. The term “machine-readable medium” shall also be taken to be a non-transitory machine-readable medium. The term “machine-readable medium” includes, but not be limited to, data repositories in the form of solid-state memories, optical media, and magnetic media.
Some portions of above description describe the embodiments in terms of algorithmic processes or operations. These algorithmic descriptions and representations are commonly used by those skilled in the data processing arts to convey the substance of their work effectively to others skilled in the art. These operations, while described functionally, computationally, or logically, are understood to be implemented by computer programs comprising instructions for execution by a processor or equivalent electrical circuits, microcode, or the like. Furthermore, it has also proven convenient at times, to refer to these arrangements of functional operations as modules, without loss of generality. In some cases, a module can be implemented in hardware, firmware, or software.
As used herein, any reference to “one embodiment” or “an embodiment” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
Some embodiments may be described using the expression “coupled” and “connected” along with their derivatives. It should be understood that these terms are not intended as synonyms for each other. For example, some embodiments may be described using the term “connected” to indicate that two or more elements are in direct physical or electrical contact with each other. In another example, some embodiments may be described using the term “coupled” to indicate that two or more elements are in direct physical or electrical contact. The term “coupled,” however, may also mean that two or more elements are not in direct contact with each other, but yet still co-operate or interact with each other. The embodiments are not limited in this context.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
In addition, use of the “a” or “an” are employed to describe elements and components of the embodiments. This is done for convenience and to give a general sense of the disclosure. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise. Where values are described as “approximate” or “substantially” (or their derivatives), such values should be construed as accurate +/−10% unless another meaning is apparent from the context. From example, “approximately ten” should be understood to mean “in a range from nine to eleven.”
Upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs. Thus, while particular embodiments and applications have been illustrated and described, it is to be understood that the described subject matter is not limited to the precise construction and components disclosed herein and that various modifications, changes and variations which will be apparent to those skilled in the art may be made in the arrangement, operation and details of the method and apparatus disclosed. The scope of protection should be limited only by any claims that issue.
This application claims the benefit of, and priority to, U.S. Provisional Patent Application Ser. No. 63/594,922, “Sheet Part Forming Components and Methods,” filed Oct. 31, 2023, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63594922 | Oct 2023 | US |
