The invention relates to a transfer device for transferring components from a feed side to a safety-critical production side where a production robot is located, the transfer device being configured to pick up components and transfer them to the production side.
From the state of the art, in particular from automotive production, it is known to use production robots that can pick up ordered components and process then on a production table or similar devices. The production robots are located on a so-called production side, which must not be entered by workers for safety reasons. The underlying problem thus consists in feeding the components to the robot in an ordered manner without the need of workers entering the production side.
Usually, this is solved by physically separating a feed side from the production area, for example by a protective fence, and providing a so-called accumulating conveyor or a chute or a similar device, generally a transfer device, from the feed side through the protective fence to the production side. In such a structure, the production plant can be provided with a container holding components, a so-called components bin, on the feed side, which contains the components in a disordered manner. A production worker may then take components from the component bin and place them onto special pallets of the accumulating conveyor or onto shelves of other devices in an ordered position. The accumulation conveyor or a similar device can then move the ordered components through the protective fence to the production side, where they can be picked up and processed by the production robot.
To automate the process, known further developments provide that the production worker is replaced by an automated station, a so-called bin-picking station. Bin-picking stations are closed units meeting all safety regulations and machine guidelines. Such bin-picking stations thus precisely automate the act of picking components from the component bin and placing components onto the special pallets of the accumulating conveyor or onto shelves of other devices.
However, the systems now available that include manual placing or bin-picking stations, accumulating conveyors and production robots, still have disadvantages, since it is a costly system with high maintenance costs that requires a lot of space.
EP 3659744 A1 discloses a production device with an external loading side and an internal processing space. Initially, a workpiece is placed from the outside, i.e., from the loading side, onto a pivotable workpiece table. This can be done manually or via a robot. The production table is then pivoted so that the workpiece can be machined inside by a machine with a machining head. However, the workpiece cannot be removed immediately from the processing robot after processing, but the workpiece table must be pivoted back again, where it can be loaded with new workpieces.
DE 202004 009601 U1 describes a turntable on which at least two consoles are mounted. The workpieces are mounted by an operator on one side of a tool plate of the console. At the same time, a robot on the other side can process the workpiece and also remove it from the console. However, this is not a device that transfers a component from a safe side to a safety-critical production side.
It is the object of the invention to create a transfer device for transferring components from a feed side to a safety-critical production side with a production robot, which can be formed more cost-effectively and requires less space.
This object is achieved by a transfer device for transferring components from a feed side to a safety-critical production side on which a production robot is located, wherein the transfer device is configured to receive at least one component or several components and to transfer them to the production side, wherein the transfer device comprises at least two component carriers that can be pivoted independently of one another, which comprise(s) at least two component receptacles for receiving a component, wherein the component carriers are each formed as elongated profiles, and wherein at least one component carrier is pivotable about an axis and moves from a loading position, in which components are able to be laid on the component receptacles from a side remote from the production side, into an unloading position, in which the components are removable from the production side.
It is preferred that the component carriers are pivotable about mutually parallel axes and are pivotable from a loading position, in which components are able to be laid on the component receptacles from a side remote from the production side, into an unloading position, in which the components are removable from the production side.
This so-called production buffer makes it possible to omit the use of accumulating conveyors or similar devices, which in particular eliminates the high investment costs and saves space. The production buffer can be implemented particularly easily thanks to the pivotable component carriers and does not require any conveyor belts or other devices, but instead transports the components simply by pivoting or rotating the component carriers from the feed side to the safety-critical production side. While the space required for a system comprising a bin-picking station, an accumulating conveyor and a production robot is approximately 15 m2, the required space can be reduced to a total of approximately 2 m2 with the device according to the invention.
In a particularly preferred embodiment, the transfer device comprises at least two component carriers that can be pivoted independently of one another. As a result, at least one of the component carriers can be constantly available for loading, while components can be removed from another component carrier by the production robot. Since the pivoting or rotating movement can also be carried out extremely quickly, there is no delay between the completion of a loading process and the time it is made available to the production robot. The advantages of the invention are even observable in the case of only a single component carrier, since the component carrier can, for example, be pivoted immediately from the unloading position to the loading position as soon as the production robot has removed a component from the component carrier, and in the loaded state it can be immediately pivoted from the loading position to the unloading position, for example before the production robot can pick up another component from the component carrier. Below, embodiment variants for a transport device with several component carriers and several component receptacles are explained, which, however, can also be used for transport devices with only one component carrier and/or only one component receptacle per component carrier.
In addition, it has been shown that the transfer device according to the invention, i.e., the production buffer, is advantageous not only in combination with a bin-picking station, but also in other applications, for example when the transfer device is loaded manually. Even in this case, the production buffer saves a considerable amount of space and reduces costs compared to accumulation conveyors or other transfer devices known from the state of the art.
The component carriers are particularly preferably pivotable about horizontal axes or about vertical axes. Furthermore, the axes can lie in a common vertical plane or in a common plane that is inclined relative to a vertical plane. If the plane of the production buffer is arranged vertically, the production buffer can, for example, form part of the side wall of the device, for example with a size of 0.2 m2. The dimensions of such a production buffer can, for example, be 990 mm×1400 mm×200 mm. If the plane of the production buffer is inclined relative to the vertical plane, the components can be picked up particularly easily by the production robot, with the space requirement for such a production buffer being around 0.6 m2. With these embodiments, a simple control for pivoting the component carrier can be achieved.
Furthermore, it is preferred that the axes of the component carriers each run through the mass centroid axes of the component carriers. This allows pneumatic or electromechanical pivoting or rotating with little effort despite the possibly strong cross-sections that are necessary and thus high weights of the component carriers.
The component carriers are particularly preferably elongated, preferably L-shaped, profiles on which the component receptacles are arranged linearly. As a result, the component carriers can be manufactured particularly easily, with a component carrier having a row or line of component receptacles.
In a further preferred embodiment, the component carriers have a first and a second carrier wall and the component receptacles are arranged in a spandrel between the first carrier wall and the second carrier wall, the first carrier wall preventing access from the production side to the component carrier in the loading position and the second carrier wall preventing access of the gripping robot to the component carrier in the unloading position. As a result, the component carriers may not only represent a receptacle for the components, but also form the protection or outer wall of the device or part of the protective fence, since the carrier walls form, in both operating positions, a partition between the interior of the device or the feed side and the production area.
In order for the production buffer to also form a continuous side wall of the device, it is preferred if the component carriers are positioned in a way that there is a gap of no more than 0.5 cm, preferably no more than 0.3 cm, between the component carriers, regardless of whether they are in the loading position or the unloading position.
Furthermore, it is particularly advantageous if the component carriers also offer impact protection in the event of incorrect operation of the production robot. This can be achieved, for example, when the component carriers are made of metal, preferably steel, and have a thickness of at least 0.5 mm. Alternatively, the component carrier could also be made of plastic or ceramic to achieve the mentioned effect.
In an advantageous embodiment, the component carriers have additional component receptacles, wherein components are able to be placed onto the additional component receptacles by the gripping robot in the unloading position of the component receptacles and components are removable from the additional component receptacles via the production side in the loading position of the component receptacles. As a result, the component receptacles on the component carrier are duplicated, so that a component located on the component receptacle can be removed by the production robot and the gripping robot can place the next component onto the additional component receptacle immediately behind or next to it. The component carrier thus has at least two component receptacles in the same longitudinal direction, as a result of which the component carrier can be loaded and unloaded at the same time at this location.
The transfer device can also include a controller which is configured to pivot empty component carriers from the unloading position into the loading position and to pivot full component carriers from the loading position into the unloading position. As a result, the method can be, on the one hand, automated and, on the other hand, optimized, since there is no pivoting of only partially loaded component carriers.
An evaluation unit can detect when a component carrier Is fully, partially or not loaded, which, as is known from the state of the art, could receive sensor signals from a plurality of sensors, each monitoring one of the component receptacles. However, due to the large number of sensors required, the plurality of control inputs required at the evaluation unit, and the complexity of the evaluation, this method can only be implemented at great expense.
In a particularly preferred embodiment of the invention, the solution according to the invention therefore comprises an evaluation unit, a camera connected to the evaluation unit and a light spot under each of the component receptacles of all component carriers, with a respective light spot being recognizable by the camera when the respective component receptacle is unoccupied and unrecognizable by the camera when a component is located on the respective component receptacle, the evaluation unit being configured to recognize a component receptacle as occupied or covered when a respective light spot is visible or not in the picture taken by the camera. This solution has the advantage that the evaluation unit must only have one control input for receiving the picture from the camera. The evaluation of the picture taken by the camera as to whether light spots are visible in the picture or not can be implemented comparatively easily.
In the last-mentioned embodiment, all light spots of a component carrier can preferably be illuminated by a single light source, preferably an LED strip, and each can be formed by openings in the area of the component receptacles, wherein each component carrier preferably comprises an additional opening through which the light source is visible, even if all component receptacles are occupied by components. This enables a simple functional check of the light source without having to remove a component from the component carrier.
In a further aspect, the invention creates a bin-picking station particularly saving space, i.e., a device comprising a transfer device according to one of the embodiments described above and a gripping robot, the gripping robot being configured to pick up a component from a container and to place the component picked up from the container on the transfer device.
In order to form the device in a closed manner, it can comprise a housing, wherein the gripping robot is enclosed by the housing and the component carrier forms a side wall of the device, wherein the container is insertable into the device via an insertion opening on the feed side. As a result, the device is formed in a particularly compact and safe manner and can be sold, in particular, as a modular unit that does not require a connection to an accumulating conveyor or the like.
Overall, a system can thus be created comprising a device and a production robot located on the production side, which is configured to pick up components from component carriers that are in the unloading position.
Advantageous and non-limiting embodiments of the invention are explained in more detail below with reference to the drawings.
The accumulating conveyor 5 moves the now ordered components 2 on the pallet 4 from the feed side 6, on which the production worker 1 is working, to the safety-critical production side 7, where staff are not allowed to enter. The feed side 6 is separated from the production side 7 by a protective fence 8. On the production side 7 there is a production robot 9 which picks up the components 2 ordered on the pallet 4 and processes them on a production table 10. This system is particularly common in the automotive industry.
It is known to replace the production worker 1 by a so-called bin-picking station reaching into the container 3 by means of a gripping robot to pick up a component 2, optionally subjecting it to a quality control, bringing it into the correct position and placing it onto the pallet 4 of the accumulating conveyor 5. The mechanics and control of the device described below, in particular the general techniques for picking up disordered components 2 from the container 3 and bringing the components 2 into a predetermined position, are known per se from the state of the art. However, the system described below has been further developed, particularly with regard to the transfer of the components 2 to the production area 7.
According to the invention, a device 11 is provided as shown in
The device 11 comprises a housing 13 with an opening 14 into which the container 3 with the components 2 can be manually or automatically inserted from the walk-in feed side 6. A gripping robot 15 with a gripping arm is provided inside the housing 13, which is configured to remove components 2 from the container 2 inserted into the device 11, optionally subject them to a quality control, for example by means of a camera and a picture evaluation unit, and move them to the transfer device 12 in an ordered position.
In analogy with the accumulating conveyor 5 of
The component receptacles 18 can, for example, include one or more centering pins and/or position adaptors for the component 2 in order to ensure the correct positioning of the components 2 on the component carrier 17. The shape of the component receptacle 18 and the mutual distance between two component receptacles 18 on a component carrier 17 is generally dependent on the shape and the dimensions of the component 2 to be placed. There are usually two to thirty, preferably four to fifteen, component receptacles 18 on a component carrier 17. Also, the number of component carriers 17 can essentially be selected as desired, preferably between two and fifteen, particularly preferably between four and ten. Particularly preferably, the number of component receptacles 18 and the number of component carriers 17 can be selected in such a way that up to a hundred components 2 can be accessible on the production side 7 at the same time.
As explained below, the component carriers 17 can each be pivoted about an axis A without any translational movement and pivoted from a loading position, in which components 2 can be placed onto the component receptacles 18 by the gripping robot 15, to an unloading position, in which the components 2 can be removed on the production side 7. Due to the pivotability of the component carrier 17, there is no need for a linear transfer device. Usually, the gripping robot 15 cannot place any components 2 onto the component receptacles 18 when the component carrier 17 is in the unloading position, and the production robot 9 cannot remove any components 2 from the component receptacles 18 when the component carrier is in the loading position. The component receptacles 18 are configured in such a way that a component 2 located thereon does not shift with respect to the component carrier 17 during pivoting.
The component carriers 17 can be pivoted about the axes A independently of one another, for which a separate control unit can be provided. The component carriers 17 can preferably be pivoted pneumatically or electromechanically. The shaft thickness of a rotary bearing can be 20 mm, for example.
Usually, an empty component carrier 17 is pivoted into the loading position and then filled by the gripping robot 15. As soon as the component carrier 17 is full, it is pivoted into the unloading position, where the components 2 can be removed by the production robot 9. Since the component carriers 17 can be pivoted independently of one another, at least one component carrier 17 can be in the unloading position and one component carrier 17 in the loading position, which can generally ensure that components 2 can be made available to the production robot 9 at any time.
A first preferred embodiment of the transfer device 12 formed as a production buffer will now be explained with reference to
It can be seen from
In the embodiment of
Coming back to
The component carriers 17 are preferably created in such a way that a penetration of an arm of the production robot 9 in case of a malfunction is prevented. For this purpose, the component carrier can be made of metal, preferably steel, and have a thickness of at least 0.5 mm. Alternative materials such as plastic or even ceramics could also be used for the component carriers, for example in order to make them particularly lightweight and therefore easily pivotable.
As a further safety measure, it can be provided that the component carriers 17 are positioned in such a way that there is a gap of max. 0.5 cm, preferably max. 0.3 cm, between the component carriers 17, regardless of whether they are in the loading position or the unloading position condition. Referring to
In the embodiment of
In the aforementioned embodiment, an additional opening 23 can be provided in the component carrier 17, through which the light source is visible, in order to generate a control light. The additional opening 23 is provided on the component carrier 17 in such a way that the control light is visible even if all component receptacles 18 are occupied by a component 2. This means that the functioning of the light source can be checked at any time. If the control light was not present, it would not be possible to distinguish whether all component receptacles 18 are occupied by a component 2 or whether the light source is not working.
As an alternative to the aforementioned embodiment, in which the presence of a component 2 on a component receptacle 18 is determined by detecting a visible or non-visible light spot 21 in the picture from a camera, the presence of a component 2 can also be detected using a programmable logic controller (PLC) with conventional sensors. The conventional sensors are, for example, light barriers, capacitive or inductive sensors. A purely mechanical detection of components 2 on the component receptacles 18 is also possible.
In all of the aforementioned embodiments, the device is configured to pick up only one type of component 2 from the container 3 and place it onto the component carrier 17. This means that all components 2 have the same dimensions and are manufactured in essentially the same way, so that all component receptacles 18 are also manufactured in the same way. In other embodiments, however, several containers 3 could be introduced into the device 11, in each of which different components 2 with different dimensions are supplied, so that, e.g., the first container 3 contains components 2 with first dimensions and the second container 3 contains components 2 with second dimensions. It can be seen that it may be necessary to adapt component receptacles 18 to the different components 2 if the component receptacles 18 are not configured as universal component receptacles for components 2 of different dimensions. For example, the device 11 can comprise at least one first component carrier 17 comprising first component receptacles 18, onto which components 2 with first dimensions can be placed, and at least one second component carrier 17 comprising second component receptacles 18, onto which components 2 with second dimensions can be placed. Alternatively or additionally, a component carrier 17 could be used, which includes both at least one first component receptacle 18, onto which components 2 with first dimensions can be placed, and at least one second component receptacle 18, onto which components 2 with second dimensions can be placed.
The gripping robot 15 can now be configured to pick up components 2 with first dimensions from the first container 3 and place them onto a first component receptacle 18, which is configured to receive corresponding components 2, and components 2 with second dimensions from the second container 3 and place them onto a second component receptacle 18, which is configured to receive corresponding components 2.
Number | Date | Country | Kind |
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21156404.2 | Feb 2021 | EP | regional |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2022/052879 | 2/7/2022 | WO |