Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
  • B21D39/02—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder
  • B21D39/021—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder for panels, e.g. vehicle doors
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
  • B21D39/02—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder
  • B21D39/021—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder for panels, e.g. vehicle doors
  • B21D39/023—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder for panels, e.g. vehicle doors using rollers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J15/00—Gripping heads and other end effectors
  • B25J15/0019—End effectors other than grippers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J9/00—Programme-controlled manipulators
  • B25J9/16—Programme controls
  • B25J9/1679—Programme controls characterised by the tasks executed

Definitions

• the present invention relates to systems for forming and joining a first sheet material to a second sheet material. More particularly, the present invention relates to a pressure-controlled roller tool and method of use in the forming and joining of sheet material.
• a further object of the present invention is to provide such a positional pressure roller tool that may be used in conjunction with a robotic arm in operation with a variety of machine cells.
• a positional pressure roller tool which is operatively associated with a programmable positioning apparatus in the form of a robotic arm and a machine cell which includes a holder for a first panel in the form of a lower nest, and a holder for a second panel in the form of an upper gate.
• the positional pressure roller tool or positional-pressure- variance-unit ["PPVU”] includes a cylinder head with a captured reciprocating piston and shaft.
• a biasing element in the form of a compression spring is located inside the cylinder and atop the piston. The biasing element urges the piston to an extending position.
• Forming steels and roller-forming tools are also attached to the end of the shaft.
• a pair of married sheet materials, A and B, is approximated onto the lower nest.
• the first sheet material A is then precision positioned by means of crowders.
• the upper gate thereafter aligns the second sheet material ⁇ with respect to the first sheet material A by known means.
• the first sheet material /4 is then securely held in place either by known means or by a vacuum system such as disclosed and claimed in PCT/US04/34238, incorporated by reference herein.
• a seaming operation executes, forming and joining the first sheet material A to the second sheet material B by means of the roller-forming tools attached to the PPVU.
• a positional program of the robotic arm orientates the PPVU in a generally perpendicular attitude with respect to the surface normal of the lower nest shape at the roller-forming tool contact point.
• the programmably positioned distance between the robotic arm's faceplate and the lower nest dictates the pressure applied to the surface of the sheet material. The distance is such that the spring will compress and exert a quantitative force back through the roller- forming tool.
• the positional program controls- the robotic arm such that the distance between the faceplate and the lower nest is variably controlled while the roller-forming tool drives along the seams of sheet material A to be formed and joined.
• the roller-forming tool pressure-forms material A to lay over material B while being supported by the lower nest. Once all the seams are formed, the joining operation is complete.
• Figure 1 is a perspective view of a machine cell incorporating a positional pressure roller tool assembly according to the preferred embodiment of the present invention
• Figure 2 is a sectional view of the roller tool assembly of the present invention taken along lines 2-2, viewed from the side of the main roller and illustrating the piston in its substantially unloaded, fully extended position;
• Figure 3 is a sectional view of the roller tool assembly of the present invention similar to that of Figure 2 but illustrating the piston in its substantially loaded, partially extended position;
• Figure 4 is a sectional view of the roller assembly taken along lines 4-4, showing the main roller and the touch-up roller, both rollers having parallel axles that are rotatably mounted through the piston shaft, the figure being taken axially along the parallel axles;
• Figure 5 is a sectional view of the sheet materials taken along lines 4-4 of
• Figure 6 is a view similar to that of Figure 5 but illustrating the materials in their formed positions.
• FIG. 1 the preferred embodiment of a machine cell, generally referenced as 10, is illustrated in a perspective view.
• the machine cell 10 includes an upper gate 20 and a lower nest 30. It should be understood that the configuration of the machine cell 10 as illustrated is preferred, but is not to be interpreted as limiting as other configurations conceivable to those skilled in the art may also be suited.
• the machine cell 10 holds two portions of sheet material so that a joining process may be undertaken without the sheet material portions being caused to shift or otherwise move out of position.
• the two portions of sheet material include a first sheet material A and a second sheet material B.
• the two sheets A and B in a combination resulting from seaming, form an integrated component, of which the first sheet material A forms the outer part or the skin and the second sheet material B forms the inner part or the support structure.
• Sheets A and B are illustrated in combination in Figure 6, discussed below.
• the first sheet material A and the second sheet material B have a generally square configuration resulting in a generally square-shaped integrated component.
• other shapes may be suitable for use in the present invention.
• the sheet materials -A, B are captured and held between the upper gate 20 and the lower nest 30.
• the sheet materials A, B are approximated onto the lower nest 30.
• the lower nest 30 includes a nest surface 32 that is fluidly connected to a vacuum source (not shown).
• the first sheet material A is then precision positioned by means of crowders 34.
• the upper gate 20 is lowered by a robotic arm or linear slide to a precise location.
• the gate aligns the second sheet material B with respect to the first sheet material A by way of alignment pins from the gate engaging master locating holes in material B.
• the first sheet material A is then held in place by a vacuum applied to its under side.
• FIG. 1 illustrates the PPVU as an assembly 50 in operational association with a robotic arm 52.
• the PPVU assembly 50 mounts rigid to a robotic arm faceplate 54 that is rotatably connected to the robotic arm 52.
• the robotic arm 52 is itself in operative association with a computer 56.
• the computer 56 preferably effects movement of the robotic arm 52 by a specific program as will be discussed further below.
• the PPVU assembly 50 includes a main roller tool 58 and a touch-up roller tool 60.
• the main roller tool 58 and the touch-up roller tool 60 may be rotatably selected depending upon the desired operation.
• a cross-section of the main roller tool 58 is shown in both Figure 2 and Figure 3.
• a cross-section of the roller assembly 50 is shown in Figure 4 and illustrates both the main roller tool 58 and the touch-up roller tool 60.
• the main roller tool 58 is generally and operatively mounted to the faceplate 54 by a reciprocating hub 62 having a piston end 64 mounted in a cylinder 66.
• the cylinder 66 is fitted rigid to the faceplate 54 of the robotic arm as is known in the art.
• Biasing element or spring 68 biases the piston end 64 away from the end wall of the cylinder 66.
• the main roller tool 58 includes an axle 70 fixedly mounted in the hub 62.
• a main roller 72 is rotatably mounted on the axle 70 by a main bearing 74.
• the axle 70 includes a main roller support flange 76 that retains the main bearing 74 against the hub 62.
• the outer diameter of the main roller 72 may be of a variety of sizes but is preferably of the 90 mm size which is known in the art as being a standard size.
• the main roller 72 includes a hardened wear surface 78.
• a face plate 80 is threaded to the main roller 72 thus locking the hardened wear surface 78 in place with respect to the main bearing 74.
• the touch-up roller tool 60 includes a spindle 82 that i ⁇ rotatably carried by the hub 62 by way of an array of bearings 84.
• the bearings 84 are disposed within a pocket 86 defined into the hub 62.
• a locking member 88 is threadably attached to one end of the spindle 82 thus capturing the bearings 84 there between.
• the bearings 84 are themselves retained in the hub 62 by a faceplate 90 that is screwed to the hub 62.
• a tool insert 92 is slidingly positionable within an aperture 94 defined in the end of the spindle 82 opposite the threaded end onto which the locking member 88 is attached.
• the tool insert 92 slip fits into the aperture 94 and is selectively locked in place with a ball lock interface 96.
• the ball lock is an industry standard configuration that allows the tool insert to be removed by pushing a ball bearing 98 via an access hole 100 back into and compressing a spring 102 against a retaining plug 104 prior to removal.
• the outer diameter of the tool 92 may be of a variety of sizes but is preferably of the 20 mm size which is known in the art as being a standard size.
• the tool insert 92 may be stepped and may have two or more surfaces of different diameters.
• the main roller tool 58 and the touch-up roller tool 60 operate in conjunction with the robotic arm and the pressure system of the present invention.
• the biasing element 68 of the roller assembly 50 urges the piston end 64 in its outwardly extended position.
• the piston end 64 may be reciprocatingly urged into the cylinder 66 by the opposing force of the material being formed.
• the biasing element (or gas-charged cylinder) 68 acts to resist the inward movement of the piston end 64.
• the bias of element (or gas-charged cylinder) 68 is linearly proportional to piston end 64. Each unit of linear distance piston end 64 moves into cylinder 66 will increase the bias of element 68 in a linear proportion. In the event that a gas- filled cylinder is used in lieu of the spring 68 a charge is built up therein and the piston end 64 moves into cylinder 66. This linear relationship is the basis for the positional pressure variance programming that the robotic arm plays. Operation [0041 ]The operation of the machine cell 10 will now be generally described. As the operation begins the upper gate 20 should already be in its elevated position, assuming that a seaming operation has already been completed and the seamed part has been removed, thus leaving the lower nest 30 empty.
• mastic as shown in Figure 5
• M a known quantity of mastic
• the mastic is utilized to provide a more complete joining of the sheet materials.
• the mastic may be joined to one of the sheets or to both as may be desired.
• Known mastics may include glass bead-filled compositions as are known in the art.
• the machine cell 10 may then be operated by a human operator or by a programmable logic controller as is known in the art. Regardless of the form of the operator, reference shall be made hereafter generically to "the operator.”
• the operator married the first sheet material A to the second sheet material B, then places the combined sheets on the nest surface 32 with the first sheet material A face down (that is, the outer surface of the sheet material A is placed onto the nest surface 32).
• the crowder assemblies 34 are then activated by operation of a second air pressure source to advance the alignment fingers to their engaged and aligning positions. So engaged, the first sheet metal A is in alignment relative to the nest surface 32. This arrangement facilitates positive micro-positioning of the first sheet material A.
• the operator then engages the robotic arm or linear slide (neither shown) to lower the upper gate 20 into an engaged position with material B.
• the robotic control provides that movement of the upper gate 20 with a precise attitude.
• a vacuum source is activated to provide a vacuum between the surface of the first sheet material A and a plurality of vacuum channels (not shown).
• the first sheet material A is thus immobilized.
• an air pressure source (not shown) is activated and the fingers of the crowder assemblies 34 are drawn away from their illustrated aligning positions to substantially horizontal positions. Thus positioned, the fingers will not interfere with the subsequent forming operation.
• the forming operation then occurs by which a seam is formed around the periphery of the combined unit of the first sheet material A and the second sheet material B.
• the forming operation is performed in two stages. First the flange F is formed from a generally upright position A to a preform position A'. Next the flange F is formed from the preform position A' to a final form position A".
• the seam S is formed to capture and thus join the first and second sheet materials A, B.
• seaming of the first sheet material A with the second sheet material B is accomplished by either the main roller tool 58 or the touch-up roller tool 60. Selection between the two of these rollers 58, 60 is made depending upon accessibility of the material to be seamed.
• the touch-up roller tool 60 may be selected in the event that the main roller tool 58 is too large for effective cornering and may thus cause undesired deformation of the sheet material B, or in the event that the surface terrain of the combined sheet materials exhibit a tight radial form that flows between inward and outward with respect to the frame, thus rendering use of the larger main roller toll 58 impractical.
• An advantage offered by the present invention lies in the off-line programming of the robotic arm 52 which controls the main roller tool 58 and the touch-up roller tool 60. As the main roller tool 58 is engaged to undertake the seaming operation, it is anticipated that the robotic arm 52 will experience a certain amount of structural deflection and backlash of its gearing that in turn introduces positional error.
• the present invention provides compensation for this error during the initial off-line programming and subsequent programming, thus resulting in accurate seaming that is highly repeatable without loss of accuracy.
• the error is cancelled by a compensated program which is loaded into the computer 56 that controls the positional articulation of the robotic arm 52 and the variable pressures of the rollers 58, 60, as they form the sheet material.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Robotics (AREA)
• Lining Or Joining Of Plastics Or The Like (AREA)
• Automatic Assembly (AREA)
• Folding Of Thin Sheet-Like Materials, Special Discharging Devices, And Others (AREA)

Applications Claiming Priority (3)

Publications (2)

Family

ID=34713740

Family Applications (1)

Country Status (3)

Families Citing this family (2)

Citations (6)

Family Cites Families (5)

• 2004
  • 2004-11-19 EP EP04811675A patent/EP1689562A4/de not_active Withdrawn
  • 2004-11-19 WO PCT/US2004/038993 patent/WO2005060493A2/en active Application Filing
  • 2004-11-19 CA CA2545684A patent/CA2545684C/en not_active Expired - Fee Related

Patent Citations (6)

Non-Patent Citations (1)

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