EP2352606A2

EP2352606A2 - Affixation tool, system and method for affixing parts to be inserted into an opening of a structural member, wherein the parts are supplied as bulk good

Info

Publication number: EP2352606A2
Application number: EP09760304A
Authority: EP
Inventors: Frank Eckstein; Martin Kluge
Original assignee: ITW Automotive Products GmbH
Current assignee: ITW Automotive Products GmbH
Priority date: 2008-11-06
Filing date: 2009-10-22
Publication date: 2011-08-10
Also published as: WO2010052602A3; DE102008056246A1; WO2010052602A2

Abstract

An affixation tool for in-bulk small parts to be inserted into a workpiece's aperture, comprising a magazine (10) receiving a plurality of the small parts in a predetermined array, a feeder (14) moving the small parts step-wise out of the magazine into an affixation position, and an insertion device (18) to insert a small part at the affixation position into the workpiece's aperture.

Description

Title of Invention: AFFIXATION TOOL, SYSTEM AND

METHOD FOR AFFIXING PARTS TO BE INSERTED INTO AN

OPENING OF A STRUCTURAL MEMBER, WHEREIN THE

PARTS ARE SUPPLIED AS BULK GOOD

[1] The present invention relates to affixing small parts present in bulk into a workpiece aperture. Such small parts illustratively may be rivets, fasteners, cable feedthroughs, grommets, bushes, muffs, sleeves or the like to be inserted into a workpiece aperture.

[2] Said small parts are present in-bulk, that is, they are contained in a pouch or a cardboard box. They are not linked to one another nor are they arrayed in order/ sequence by means of special packaging or other steps. Such small parts typically are affixed manually. They may be either directly seized manually and inserted into the particular workpiece aperture, or a special affixation tool may be used to seize the small part or receiving it. Such a special affixation tool typically is manually guided to the workpiece aperture and illustratively adjusts the workpiece to a snap-in pressure. A known example is a blind riveting implement receiving a manually inserted rivet.

[3] In alternative manner, it is also known to use such small parts available in prefinished form. Illustratively a plurality of plastic small parts may be made by injection molding, small links remaining between said small parts. Illustratively magazine strips may be made that way. Alternatively the small parts may be held in place in special arrays within special packages. Such manufacturing steps facilitate automated small-parts affixation. On the other hand small parts combined into magazine-strips are unsuitable for manual affixation. Contrary to the case of in-bulk small parts, such magazine-strips do not allow easily manually seizing an individual small part.

[4] Special efforts already have been made, in particular in the automobile industry, to partly or entirely automate manual affixation procedures to save time and money. At the same time, the increasing number of car models demands high flexibility. Accordingly a particular small part, or component, should if possible be suited for automated or partly automated affixation as well as for a manual one.

[5] Accordingly it is the objective of the present invention to create an affixation tool for in-bulk small parts to be inserted into a workpiece aperture, furthermore a corresponding method allowing both fully and partly automated affixation, without thereby hampering manual affixation.

[6] This objective is attained by the affixation tool defined by the features of claim 1.

Advantageous embodiment modes are defined in the subsequent dependent claims.

[7] The affixation tool of the present invention for in-bulk small parts to be affixed into a workpiece aperture comprises

[8] • a magazine receiving, in a predetermined array, a plurality of small parts,

[9] • a feeder step-wise moving the small parts from the magazine into an affixation position, and

[10] - an insertion device inserting the small part at the affixation position into the workpiece aperture.

[11] The small parts are in-bulk, that is they are loose, not linked to each other, or arrayed in a special way. In particular they may be easily seized manually. In particular these small parts may be made of plastic and be made integrally.

[12] The affixation tool's magazine may receive a plurality of small parts configured in a predetermined order. Illustratively too, the small parts may be manually inserted into the magazine. Said magazine acts as an appropriate receptacle matched in such a way to the small parts to be received that they may be filled as a predetermined array into the magazine. The magazine may be sealed and enclose the small parts on all sides. Said magazine also may be open and hold in place or enclose said small parts only partially.

[13] The small parts are moved stepwise from the magazine into an affixation position.

Each affixation step moves one small part into the affixation position.

[14] Affixation proper is carried out by inserting the particular small part that is in the affixation position into the workpiece's aperture using an insertion device. Following insertion, a new feeding step takes place in the course of which another small part arrives at the affixation position. In one implementing mode, the feeder only moves one small part at a time and carries it in a single moving step from the magazine to the affixation position. However a larger number of small parts also may be moved simultaneously by the feeder. In the latter case, one small part is moved from the magazine into the feeder and another small part from the feeder into the affixation position. Again, the said magazine may be constituted by a portion of the feeder.

[15] The affixation tool of the present invention allows quickly affixing sequentially a predetermined number of small parts determined by the size of said magazine. The small parts need not be handled manually between the individual affixation procedures. Compared with strictly manual affixation — namely requiring each small part being individually retrieved from a storage container and being individually moved to an affixation position of the affixation tool — this feature offers a considerable saving in time. Moreover it is possible to rigorously monitor the number of installed small parts. There are no links between the small parts that would entail additional waste or other finishing steps.

[16] In one embodiment mode of the present invention, the magazine can be inserted into or attached to the affixation tool. Basically the magazine need not be separate from the affixation tool. Illustratively the magazine may be in the form of a receiving space integrated into the affixation tool. In that case the affixation tool can't be used for affixation while the magazine is being filled. In order to assure substantially continuous affixation operation, advantageously two affixation tools shall be used, one of which being filled while the other is available for affixation. Alternatively, an insertable or attachable magazine allows speedily exchanging an emptied one with a full one. Accordingly the affixation procedure may continue following a merely short interruption. While the previously empty magazine is being replenished, the affixation tool is wholly available.

[17] In another embodiment mode of the present invention, a magazine's inside space matches the geometry of the small parts in a manner that said small parts may be received in single file in the magazine. A single file array of said small parts easily allows both removing them individually to be fed into the affixation position and filling them individually into the magazine. Matching the magazine inside pace to the geometry of the small parts assures that these small parts remain in the predetermined array within the magazine. In particular the single file array may be such that these small parts shall touch one another. In this manner each small part may directly push the small part immediately ahead of it in the direction to the affixation position.

[18] In yet another embodiment of the present invention, the feeder is fitted with a guide and a drive spring. Illustratively the feeder may comprise a rectilinear or nearly rectilinear guide rail. Moving the small parts along this rail is implemented by a drive spring, for instance a compression spring. In this manner the present invention offers a very simple feeder.

[19] In another embodiment mode of the present invention, the guidance matches the geometry of the small parts in a way that said parts can be moved in single file in their longitudinal direction in which they shall be inserted into the workpiece. In this manner they already move in the same direction while being moved toward the affixation position in which subsequently they shall be inserted into the workpiece's aperture. This configuration simplifies moving the small parts in their appropriate attitude into the affixation position.

[20] In an alternative embodiment mode of the present invention, the feeder is fitted with a moving belt having defined receiving positions for said small parts. The moving belt in particular may be an endless feed belt. Each moved small part passes from the magazine into one of the defined receiving positions and from there is moved to the affixation position. Consequently the small parts are moved in simple and monitored manner.

[21] In another embodiment mode of the present invention each retention position is associated with a seat for a pin and/or a clamp to immobilize one small part in said retention position. The seat geometry matches in particular the geometry of the small parts to be processed. The embodiment variation including a pin is especially appropriate for small parts comprising a corresponding cavity to be engaged by the pin. The variation comprising the clamp is especially advantageous for small parts that are well suited to be clamped from the outside, for instance in the zone of a flange. When moving the small parts from the magazine to the affixation position, such seats each may engage a small part and keep it in place relative to the feed belt until the affixation position is reached where the small part remains and said engagement is dissolved.

[22] In a further embodiment of the present invention, the said seat is designed in a way that the small parts are arrayed in single file on the feed belt and transversely to their longitudinal direction in which they must be inserted into the workpiece aperture. This configuration enhances engaging/disengaging a small part along a curve of the path it is following, for instance at a roller supporting said belt.

[23] In another design of the present invention, the insertion device is fitted with a dis- placeable bar or bolt which inserts one small part at a time from the affixation position into the workpiece aperture. The bar/bolt applies the force on the small part required to insert it into the aperture. If the driving force is pneumatic or pneumatic/hydraulic, said bar may be a piston /plunger rod. An electro-mechanical drive also is appropriate. It is understood that the bar/bolt drive may be manually triggered by means of a pushbutton or another triggering element, in which case an electronic control unit might be integrated into the affixation tool and drive the insertion device.

[24] In one design of the present invention, the affixation tool is a manually operated unit fitted with a grip. In other words, it is operated manually. This feature offers maximally possible flexibility when operating said element.

[25] Alternatively or additionally, the affixation tool may comprise an attachment jig to attach the affixation tool to a robot arm. In this case the operation of the affixation tool also may be automated. This design is especially advantageous in that the robot is spared the difficult handling of the individual small parts. Automation by robot is easily implemented using the affixation tool.

[26] The above problem also is solved by a system which is used to affix in-bulk small parts to be inserted into a workpiece's aperture and which is defined by the features of claim 12. Advantageous modes of implementation for said system are defined in the ensuing dependent claims.

[27] The system of the present invention comprises:

[28] • a filling station which is fitted with a receptacle for a supply of small parts, further with individuating and ordering devices for the small parts and a filling element, and

[29] • an affixation tool comprising a magazine receiving a plurality of small parts, where

[30] • the magazine, or the affixation tool jointly with the magazine, when in a filling position, can be attached to the filling station and be automatically filled from this filling station.

[31] The small parts are moved from the individuation device to the ordering device and from there to the filling station.

[32] The system of the present invention allows extensively automating the affixation procedure because individuation and ordering inclusive filling the affixation tool's magazine may be carried out in fully automated manner. Manually dealing with the in- bulk small parts no longer is required.

[33] In a preferred embodiment mode of the present invention, a support is mounted to the filling station and keeps the magazine respectively the affixation tool in the filling position. In principle the magazine respectively the affixation tool with the magazine also might be attached manually to the filling station and be kept in a filling position. However this procedure is simplified using a special support.

[34] In one design of the present invention, the filling means is fitted with a slider moving one small part a time from the ordering device into the magazine. A slider is a simple practical solution to the problem of transferring the previously scattered small parts in a controlled/monitored way into the magazine.

[35] In another design of the present invention, the individuation device is a stepping conveyor or a vibrating conveyor. A vibratory bowl feeder (Vibrationswendelfδrderer) is also suitable. The said feed means individuate the in-bulk small parts.

[36] In one design, the ordering device is an ordering rail. This ordering rail may contain one or more ordering elements that move the small parts into a predetermined position.

[37] One design of the present invention configures a verifying system in the zone of the ordering element to check the small parts' appropriate position and/or nature. Such verification in particular may relate to the kind and size of the small parts and their complete and defect- free finish. When the verification system detects a defect or deviation, the particular small part may be eliminated automatically. This system assures that only small parts of full quality shall be used both to fill the magazine and in further processing.

[38] In one design of the present invention, the geometry of the affixation tool is defined in claims 1 through 11. The details were already mentioned above.

[39] The above objective also shall be attained by the method claimed by the features of claim 19 relating to affixing in-bulk small parts to be inserted into a workpiece's aperture. Advantageous modes of said method are defined in the subsequent dependent claims.

[40] Said method comprises the following stages:

[41] • filling an affixation tool's magazine with a plurality of small parts in a predetermined array, [42] • inserting the particular small part in its affixation position into the workpiece's aperture using the affixation tool's insertion device.

[43] Illustratively the magazine may be filled manually. The advantages offered by the method of the present invention and the features of the means implementing said method already were mentioned above.

[44] In one mode of implementation of the present invention, after having been filled, the magazine is inserted into the affixation tool or attached to it. This procedure allows using the affixation tool independently of magazine filling.

[45] In another mode of the method of the present invention, after having been filled into the magazine, the small parts are moved step-wise out of the magazine into an affixation position of the affixation tool. Such a feed assures always that one small part shall be in the affixation position. Preferably the small parts being moved into the affixation position shall be arrayed in single file in their longitudinal direction in which they shall be inserted into the workpiece's aperture, or transversely to said longitudinal direction. In this process these small parts may touch one another or be spaced apart.

[46] In a further implementing mode of the method of the present invention, each small part being moved into the affixation position is engaged by a pin or a clamp.

[47] One implementing mode of the method of the present invention prescribes that the automated filling of the magazine includes the following features:

[48] • a supply of small parts is filled into a filling station

[49] • the small parts in the filling station is individuated and arrayed

[50] • the magazine of the affixation tool comprising it is attached to the filling station

[51] • the magazine is automatically filled with a plurality of small parts, and

[52] • the affixation tool comprising the magazine is removed from the filling station respectively the magazine is removed from the filling station.

[53] In a further implementing mode of the method of the present invention, the position and the nature of each small part is checked after these small parts have been arrayed.

[54] In one implementing mode of the method of the present invention, in the case of the magazine being filled automatically, each small part is pushed by a filling station slider into the magazine.

[55] The present invention is elucidated below in relation to illustrative embodiments and modes of implementation shown in the four appended drawings.

[56] Fig. 1 shows an affixation tool of the invention comprising a feed system that includes a drive spring,

[57] Fig. 2 shows another affixation tool of the invention wherein the feed system is fitted with an endless feed belt,

[58] Fig. 3 shows a filling station of the invention fitted with a step feeder, and

[59] Fig. 4 shows another filling station of the invention fitted with a vibrating bowl feeder.

[60] The same references are used for corresponding components of the different illustrative embodiment modes.

[61] The affixation tool of Fig. 1 comprises a magazine 10 holding a number of small parts 12 arrayed in single file. The small parts 12 shall be inserted into apertures of automobile bodies and are made entirely of plastic and commercially available in-bulk, that is loose, not linked to one another, nor in any special array. Within said magazine, the small parts 12 are arrayed single-file in their longitudinal direction along which they should be inserted into the apertures. Within the magazine 10, these small parts are directly bounding and touching each other.

[62] An especially simple embodiment of a feeder 14 is a compression spring exerting a force on the back side of the rearmost small part 12 within the magazine. The affixation tool's affixation position is denoted by 16. After the particular small part 12 previously at the affixation position 16 has been inserted, the feeder 14 moves forward, in steps, all the small parts 12 within the magazine 10, whereupon a further small part 12, situated at the very front end of the magazine 10 reaches the affixation position 16.

[63] The small part at the affixation position 16 is inserted by means of a pin 18 or the like into an aperture of a workpiece. The pin 18 is guided within a cylinder 20 and driven by compressed air. The compressed air is fed from a compressed air hookup 22 to the affixation tool and is fed through a compressed air conduit 24 to the cylinder 20.

[64] A manually operable trigger 26 is situated ergonometrically at the front side of the grip 28. The affixation tool further contains a control 30 driving and/or monitoring the insertion and respectively the feed process.

[65] The feeder's compression spring 14 is configured within the magazine 10 and runs from the rear end of a small part 12 to a locking element 32 which can be locked in the rear end of the affixation tool. The locking element 32 may be opened and the compression spring 14 can be removed from the magazine 10 in order to fill it.

[66] The affixation tool shown in a second embodiment mode in Fig. 2 differs from the first embodiment mode by the geometry of both the magazine and the feeder. In the latter case the feeder is an endless belt 34 driven by a roller 36. The feeder belt 34 is fitted with a plurality of equidistant receiving elements in the form of pins, not shown in any detail, that keep each small part 12 in place relative to said belt. The segment of the feeder belt 34 shown at the top of Fig. 2 comprises a plurality of equidistant small parts 12 and constitutes the affixation tool's magazine. This magazine is open at the top, as a result of which the small parts 12 project upward from it and allow visually checking the small parts' fill-level at any time. The small parts 12 detach off the feed belt 34 in the region of a reversing roll 38 reversing said belt in the front zone of the affixation tool and then they arrive at the affixation position 16. [67] Fig. 3 shows an illustrative embodiment of a filling station comprising a step feeder to individuate in-bulk small parts 12. The step feeder 40 moves the small parts out of an omitted receptacle zone that previously received the in-bulk small parts 12. Following their individuation by the step feeder 40, the individuated small parts 12 reach an arraying/ordering rail 42 wherein each small part assumes its own accurately defined position. A verifying system 44 is configured in the region of the ordering rail 42 to check the proper position and nature of the small parts 12. Illustratively this verifying system 44 is optical.

[68] An affixation tool's magazine is denoted in dashed lines by the reference 46 and alone or in conjunction with the said tool shall be kept by a support 48 against the filling station. A slider 50 moves a small part 12 at each of its sliding steps out of the ordering rail 42 into the magazine 46 of the affixation tool. The slider 50 is driven pneumatically or electromagnetically and is controlled by a mechanical knob or an optical system. Preferably the slider 50 shall be activated until the magazine 46 has attained a given fill level. Then the magazine 46 respectively the affixation tool linked to it can be separated from the support 48 and the affixation of the small parts 12 by the affixation tool may begin.

[69] Fig. 4 shows a further embodiment mode of a filling station which instead of a step feeder comprises a vibratory bowl feeder 52. This feeder 52 moves the small parts 12 from a central receiving zone collecting the in-bulk small parts 12 into an ordering rail 42. In said ordering rail, said small parts are moved by an ordering element 54 into a defined position. The embodiment of Fig. 4 is similar to that of Fig. 3.

Claims

[Claim 1] Affixation tool for in-bulk small parts (12) to be inserted into a workpiece's aperture, comprising

• a magazine (10) to receive a plurality of small parts (12) in a predetermined array,

• a feeder stepwise moving the small parts from the magazine (10) into an affixation position (16), and

• an insertion device which inserts the small part (12) situated in the affixation position (16) into the workpiece's aperture.

[Claim 2] Affixation tool as claimed in claim 1, characterized in that the magazine is insertable into or attachable to the affixation tool.

[Claim 3] Affixation tool as claimed in either of claims 1 and 2, characterized in that an internal space of the magazine (10) is matched to the geometry of the small parts (12) in a manner that said parts may be received in a single-file array in the magazine (10).

[Claim 4] Affixation tool as claimed in one of claims 1 through 3, characterized in that the feeder comprises a guide and a drive spring (14).

[Claim 5] Affixation tool as claimed in claim 4, characterized in that the guide matches the geometry of the small parts (12) in a manner that they can be arrayed single-file in the guide in their longitudinal direction in which they must be inserted into the workpiece's aperture.

[Claim 6] Affixation tool as claimed in one of claims 1 through 3, characterized in that the feeder comprises a feed belt (34) with defined small-parts receiving positions.

[Claim 7] Affixation tool as claimed in claim 6, characterized in that each receiving position is associated with a pin and/or a clamp and that the receiving means keeps a small part (12) in place in the receiving position.

[Claim 8] Affixation tool as claimed in claim 7, characterized in that the receiving means are designed in a way that the small parts (12) are arrayed in single file on the feed belt (34) transversely to their longitudinal direction in which they must be inserted into the workpiece's aperture.

[Claim 9] Affixation tool as claimed in one of claims 1 through 8, characterized in that the insertion device comprises a displaceable bar or a dis- placeable bolt (18) that inserts one at a time one small part (12) from the affixation position into the workpiece aperture.

[Claim 10] Affixation tool as claimed in one of claims 1 through 9, characterized in that the affixation tool is a manually operable unit fitted with a grip

(28).

[Claim 11] Affixation tool as claimed in one of claims 1 through 10, characterized in that the affixation tool includes an attachment device to attach said affixation tool to a robot arm.

[Claim 12] A system for affixing in-bulk small parts (12) to be inserted into a workpiece's aperture, comprising

• a filling station fitted with a receptacle for a supply of small parts (12), an individuating and ordering device for the small parts (12), and a filling means,

• an affixation tool fitted with a magazine (10) receiving a plurality of the small parts (12), where

• when in a filling position, the magazine (10), or the affixation tool (10) together with the magazine (10), is attachable to the filling station, allowing automated filling by the filling means.

[Claim 13] System as claimed in claim 12, characterized in that a support (48) is configured at the filling station and holds in place the magazine (10) respectively the affixation tool when in the filling position

[Claim 14] System as claimed in either of claims 12 and 13, characterized in that the filling means comprises a slider (50) moving each small part (12) from the ordering device into the magazine.

[Claim 15] System as claimed in one of claims 12 through 14, characterized in that the individuation device is a step feed (40) or a vibrating feed (52).

[Claim 16] System as claimed in one of claims 12 through 15, characterized in that the ordering device is an ordering rail (42).

[Claim 17] System as claimed in one of claims 12 through 16, characterized in that a verification system (44) is configured in the region of the ordering device and checks the appropriate position and/or the nature of the small parts (12).

[Claim 18] System as claimed in one of claims 12 through 17, characterized in that the affixation tool is designed in the manner defined in one of claims 1 through 11.

[Claim 19] A method to affix in-bulk small parts (12) being inserted into a workpiece's aperture, comprising the stages below:

• filling a magazine (10) of an affixation tool with a plurality of small parts (12) in a predetermined array, and

• inserting the particular small part (12) being in the affixation position into the workpiece's aperture using an insertion device of the affixation tool.

[Claim 20] Method as claimed in claim 19, characterized in that, upon being filled, the magazine (10) is inserted into the affixation tool or attached to it.

[Claim 21] Method as claimed in either of claims 19 and 20, characterized in that after filling the magazine (10), the small parts (12) are moved step-wise out of the magazine (10) into an affixation position (16) of the affixation tool.

[Claim 22] Method as claimed in claim 21, characterized in that when being moved into the affixation position (16), the small parts (12) are arrayed single file in their longitudinal direction in which they shall be inserted into the workpiece aperture.

[Claim 23] Method as claimed in claim 21, characterized in that when being moved into the affixation position (16), the small parts (12) are arrayed in single file transversely to their longitudinal direction in which they must be inserted into the workpiece's aperture.

[Claim 24] Method as claimed in one of claims 21 through 23, characterized in that each small part (12) when being moved into the affixation position (16) is engaged by a pin or a clamp.

[Claim 25] Method as claimed in one of claims 19 through 24, characterized in that filling the magazine comprises the following steps:

• a supply of small parts (12) is filled into a filling station.

• the small parts (12) are individuated and ordered within the filling station,

• the magazine (10) or the affixation tool fitted with the magazine (10) is attached to the filling station,

• the magazine (10) is automatically filled with a plurality of small parts (12), and

• the affixation tool fitted with the magazine (10) is removed from the filling station respectively the magazine (10) is removed from the filling station.

[Claim 26] Method as claimed in claim 25, characterized in that after the small parts (12) have been ordered, a verification is run on each small part's position and/or nature.

[Claim 27] Method as claimed in either of claims 25 and 26, characterized in that when the magazine (10) is filled in automated manner, each single small part (12) is pushed by a filling station slider (50) into the magazine (10).