GB2388565A

GB2388565A - Conveyor system for use in laser welding process

Info

Publication number: GB2388565A
Application number: GB0312759A
Authority: GB
Inventors: Christopher J Wright; Warren Perry
Original assignee: Honda Canada Inc
Current assignee: Honda Canada Inc
Priority date: 2001-08-31
Filing date: 2002-08-29
Publication date: 2003-11-19
Anticipated expiration: 2022-08-29
Also published as: GB2388566A; GB0406617D0; GB2396324B; GB0312766D0; GB2388566B; GB2388565B; GB2396324A; GB0312759D0

Abstract

A conveyor system comprises <SL> <LI>(i) a continuous magnetic conveyor 62,64; <LI>(ii) first and second lateral positioning arms 66,68 for positioning a respective side edge of a blank and a longitudinal positioning assembly 122 for positioning either a leading or a trailing edge on the blank, said lateral positioning arms and longitudinal positioning assembly being incrementally driven by servo positioning means 66a, (68a, figure 22; 121, figures 20a and 20b); and <LI>(iii) servo control means for controlling the servo positioning means and enabling adjustment of the movement of the servo positioning means according to the dimensions of successive groups of blanks being transported by the conveyor system. </SL> A laser welding system and method in which upstream and downstream clamps are used to align and retain blanks during welding, and a method and system for delivering blanks to a processing station, wherein a reject mechanism is provided for when more than one blank is picked up for transfer onto a conveyor, are also described.

Description

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-1- 2388565

IMPROVEMENTS TO LASER WELDING SYSTEM

BACKGROUND OF THE INVENTION

1. FIELD OF THE INVENTION

The present invention relates to processing systems and more particularly, but not necessarily exclusively to welding systems to manufacture tailored blanks.

2. DESCRIPTION OF THE RELATED ART

The automobile industry has, over the years, achieved significant improvements in the operating efficiency of the automobiles they produce. This has, in large part, been achieved by the reduction in the weight of the vehicle while maintaining its 15 structural integrity. A major proportion of the weight of the vehicle is from its steel components, such as the chassis and doors, hood and trunk lids. Often, there are areas in the structure of these components that need to remain of a greater thickness, such as in the region of the door hinges, while there are other areas, such as in the door frame, that can be of relatively thinner wall. It is common in this case to 20 reinforce the otherwise relatively thin door frame in the regions to carry the hinges with a stiffener to provide the necessary reinforcement. However, this step increases the parts count and is a source for additional cost.

The automobile industry has, in recent years, been working to implement a welding 25 process to fabricate what is popularly known as a tailored blank which has a relatively thick portion which is welded to a relatively thin portion, so that it can be later stamped into a part with a thick portion being in place to provide strength, reduce the overall part count and weight.

A significant improvement to laser welding lines is disclosed in U.S. Patent 6204469 entitled LASER WELDING SYSTEM, assigned to HONDA GIKEN KOGYO KABUSHIKI KAISHA. The subject matter of this patent is incorporated herein by ( reference. This will be referred to as the Honda '469 patent.

While the system described in the '469 patent has provided a substantial increase in the speed, accuracy and integrity of tailored blanking welds, there is a continuing need to make further improvements, particularly in the speed of the operation.

Accordingly, the present invention seeks to improve certain aspects of the welding processes such as those used to form tailored blanks.

SUMMARY OF THE INVENTION

In one of its aspects a laser welding system, comprising: - a travel path to carry a first blank and a second blank, the first blank having 15 a first weld surface and the second blank having a second weld surface, the first and second blanks being ready to be welded together to form a weld seam along the first and second weld surfaces; - an upstream clamp assembly and a downstream clamp assembly positioned 20 on the travel path; - each of the upstream and downstream clamp assemblies being movable to an open position to allow the first blank to pass through the upstream clamp assembly to a first location within the downstream clamp assembly; 25 - a laser welding source directed at a weld location on the travel path between the upstream and downstream clamp assemblies; - at least one locating means operable to locate the first weld edge adjacent 30 the weld location; - first displacement means to displace the first weld edge against the locating means; - the downstream clamp assembly being movable from the open position to a closed clamped position to clamp the first blank with the first weld edge adjacent the weld location; - the locating means being operable to be withdrawn from the travel path; - the upstream clamp assembly being movable from the open position to an 10 intermediate position, which is selected to guide the second blank to pass through the upstream clamp assembly in a substantially coplanar relationship with the first blank so that the second weld edge makes contact with, but not past, the first weld edge; - second displacement means to displace the second blank to a location adjacent the weld location where the second weld edge abuts the first weld edge; - the upstream clamp assembly being movable from the intermediate position 20 to a closed clamped position to clamp the second blank; - the laser welding unit operable to fuse the first and second weld edges blanks together.

In one embodiment, the system further comprises first and second lateral positioning means for respectively positioning the first and second blanks relative to the travel path. Each blank has a pair of side edges and each lateral positioning means includes a pair of lateral abutment members, each for engaging a corresponding side edge, and a lateral servo positioner for positioning each lateral abutment member. Lateral 30 control means is provided for incrementally controlling the lateral servo positioners.

Each of the lateral abutment members includes an upwardly directed flange and a plurality of stop members mounted on the flange. (

In one embodiment, each of the claim assemblies includes an upper clamp beam and a lower clamp beam, a plurality of clamp elements fastened to the upper beam and a clamp drive unit for displacing the upper clamp beam relative to the lower clamp between the open and closed positions.

In one embodiment, the first displacement means includes at least one first engagement portion for engaging the first blank and a first drive portion for driving the first engagement portion. The first engagement portion includes a first 10 engagement member, in the form of an upwardly directed flange and a blank abutment member mounted on the flange, for engaging an edge on the first blank opposite the first weld edge and the first drive portion includes a first servo positioner which is aligned for movement along the travel path for displacing the first engagement member; and first control means for incrementally controlling the 15 first servo positioner. A first actuator unit is provided for actuating the blank abutment member between an operable position in the travel path and an inoperable position below the travel path.

In one embodiment, the second displacement means includes at least one second 20 engagement portion for engaging the second blank and a second drive portion for driving the second engagement portion. The second engagement portion includes a second engagement member, in the form of an upwardly directed flange and a blank abutment member mounted on the flange, for engaging an edge of the second blank opposite the second weld edge and the second drive portion includes a second servo 25 positioner which is aligned for movement along the travel path for displacing the second engagement member; and second control means for incrementally controlling the second servo positioner. A second actuator unit is provided for actuating the blank abutment member between an operable position in the travel path and an inoperable position below the travel path. 30 In one embodiment, the locating means includes a locating member movable between an operable position in the travel path and an inoperable position below the travel path and a locating drive assembly for driving the locating member between the operative and inoperative positions. The locating drive assembly has a carriage member mounted for lateral movement relative to the travel path on a third servo positioner, the carriage supporting a vertically oriented actuator with an output shaft 5 coupled to the locating member. A third control means is also provided for incrementally controlling the third servo positioner.

In still another of its aspects, the present invention provides a method of welding a pair of blanks, comprising: - a step for providing a travel path to carry a first blank and a second blank; - a step for providing an upstream clamp assembly and a downstream clamp assembly positioned on the travel path; 15 - a step for opening the upstream and downstream clamp assemblies; - a step for conveying a first blank along the travel path and through the upstream clamp assembly to the downstream clamp assembly; 20 a step for positioning a laser welding unit at a weld location between the upstream and downstream clamp assemblies; - a step for interrupting the travel path at the weld location with at least one 25 blank locator; - a step for displacing the first blank until its trailing to-be-welded edge abuts the locator; - a step for clamping the downstream clamp assembly to clamp the first blank in its position against the locator; ( - a step for withdrawing the locator from the travel path; - a step for moving the upstream clamp assembly to an intermediate position; - a step for conveying a second blank along the travel path to the upstream clamp assembly; - a step for displacing the second blank until its leading to-be-welded edge makes edge-to-edge contact with, but does not pass over, the trailing to-be10 welded edge of the first blank; - a step for closing the upstream clamp assembly; and - a step for operating the laser welding unit to form a weld seam along the abutting edges of the first and second blanks. 15 In still another of its aspects, the present invention provides a laser welding system, comprising: - a travel path to carry a first blank and a second blank; 20 - an upstream clamp assembly and a downstream clamp assembly positioned on the travel path; - each of the upstream and downstream clamp assemblies being movable to 25 an open position to allow the first blank, in a first step, to pass through the upstream clamp assembly and be delivered to the downstream clamp assembly; - a laser welding unit positioned at a weld location between the upstream and 30 downstream clamp assemblies; at least one locating means operable, in a second step, to interrupt the travel path at the weld location; - first displacement means operable, in a third step, to displace the first blank until its trailing to-be-welded edge abuts the locating means; - the downstream clamp assembly movable, in a fourth step, from the open position to a closed clamped position to clamp the first blank; - the locating means operable, in a fifth step, to be withdrawn from the travel path; - the upstream clamp assembly movable, in a sixth step, from the open position to an intermediate position, to allow a second blank to be delivered to the upstream clamp assembly; - second displacement means, operable in a seventh step with the upstream 15 clamp assembly to displace the second blank until its leading to-be- welded edge makes edge-to-edge contact therewith, while guiding constraining movement of the second blank to prevent the second blank from passing over the trailing to-be-welded edge of the first blank; - the upstream clamp assembly movable, in an eighth step, from the intermediate position to a closed clamped position to clamp the second blank; - the laser welding unit operable, in a ninth step, to fuse the first and second 25 blanks together along their abutting edges.

In still another of its aspects, the present invention provides a clamping system, comprising: - a travel path to carry a first blank and a second blank; - an upstream clamp assembly and a downstream clamp assembly positioned on the travel path; - each of the upstream and downstream clamp assemblies movable to an open position to allow the first blank, in a first step, to pass through the 5 upstream clamp assembly and be delivered to the downstream clamp assembly; - at least one locating means operable, in a second step, to interrupt the travel path between the upstream and downstream clamp assemblies; 10 - first displacement means operable, in a third step, to displace the first blank until one edge abuts the locating means; - the downstream clamp assembly movable, in a fourth step, from the open 15 position to a closed clamped position to clamp the first blank; the locating means operable, in a fifth step, to be withdrawn from the travel path; - the upstream clamp assembly movable, in a sixth step, from the open position to an intermediate position, to allow a second blank to be delivered to the upstream clamp assembly; - second displacement means operable, in a seventh step with the upstream 25 clamp assembly to displace the second blank until one edge makes edge- toedge contact therewith, while constraining movement of the second blank to prevent the second blank from passing over the edge of the first blank; and - the upstream clamp assembly movable, in an eighth step, from the 30 intermediate position to a closed clamped position to clamp the second blank.

In still another of its aspects, the present invention provides a method of processing a pair of blanks along a pair of abutting edges, comprising: - a step for providing a travel path to carry a first blank and a second blank; - a step for providing an upstream clamp assembly and a downstream clamp assembly positioned on the travel path; - a step for opening the upstream and downstream clamp assemblies; 10 - a step for conveying a first blank along the travel path and through the upstream clamp assembly to the downstream clamp assembly; - a step for positioning a processing unit between the upstream and 15 downstream clamp assemblies; - a step for interrupting the travel path adjacent the processing unit with at least one blank locator; - a step for displacing the first blank until its trailing to-be- processed edge abuts the locator; - a step for clamping the downstream clamp assembly to clamp the first blank in its position against the locator; 25 - a step for withdrawing the locator from the travel path; - a step for moving the upstream clamp assembly to an intermediate position; - a step for conveying a second blank along the travel path to the upstream clamp assembly; ( - a step for displacing the second blank until its leading to-be- processed edge makes edge-to-edge contact with, but does not pass over, the trailing to-beprocessed edge of the first blank; - a step for closing the upstream clamp assembly; and - a step for operating the processing unit to process the abutting edges of the first and second blanks.

In still another of its aspects, there is provided a conveyor system for delivering, successively, two groups of blanks of different dimensions along a travel path to a downstream processing station and for orienting each blank to arrive at the station in a precisely controlled orientation, comprising: - a continuous magnetic conveyor; - first and second lateral positioning arms, each for positioning one corresponding side edge of each blank, each of the lateral positioning arms being incrementally driven by first and second servo positioners respectively; 20 - the first and second servo positioners being movable between an inoperative position and an operative blank-engaged position, wherein the blank-engaged position is selected to locate each blank of the first group in a precisely controlled first orientation and each blank of the second group in a 25 precisely controlled second orientation; - a longitudinal positioning assembly operable for positioning either a leading edge or a trailing edge on the blank, said longitudinal positioning assembly being incrementally driven by a third servo positioner; 30 - servo control means for controlling the first, second and third servo positioners, said control means being operative in: !' -1 1 - a first phase to adjust the operative and inoperative positions according to the dimensions of the blanks in the first group, - a second phase to shuttle the first and second servo positioners between their inoperative and operative positions; - a third phase to adjust the operative and inoperative positions according to the dimensions of the blanks in the second group; and 10 - a fourth phase to shuttle the first and second servo positioners between their inoperative and operative positions.

In one embodiment, each of the lateral positioning arms includes an upwardly 15 directed frame member and a plurality of stop members mounted on the frame member. The magnetic conveyor has a travel path and the longitudinal positioning assembly further comprises a carriage mounted for travel along the travel path. A plurality of setting pins are provided along with one or more drive units for driving the setting pins between an operative position interrupting the travel path and an 20 inoperable position below the travel path. The setting pins are located at a position in the travel path to engage the trailing edge of the blank.

In still another of its aspects, there is provided a method for delivering, successively, two groups of blanks of different dimensions along a travel path to a downstream 25 processing station and for orienting each blank to arrive at the station in a precisely controlled orientation, each group of blanks having two sets of common blanks, comprising: - providing a conveyor arrangement to convey the blanks along a travel path; 30 - providing a first pair of lateral positioning arms on opposite sides of the travel path at a first location; ( - providing a second pair of lateral positioning arms on opposite sides of the travel path at a second location; - incrementally controlling the position of each of the arms by a servo positioner; - processing the blanks of the first group by: - presetting the parameters of the servo positioner to define an inoperative position for each arm and an operative position wherein, in the operative position, the arms engage opposing side edge of a corresponding blank to locate the corresponding blank of the first group in a precisely controlled orientation; 15 - delivering, successively, each blank of the first set to the first location on the travel path; delivering, successively, each blank of the second set to the second 20 location on the travel path; - processing the blanks of the second group by; - presetting the parameters of the servo positioner to define an 25 inoperative position for each arm and an operative position wherein, in the operative position, the arms engage opposing side edge of a corresponding blank to locate the corresponding blank of the second group in a precisely controlled orientation; - delivering, successively, each blank of the first set to the first location on the travel path; and ( delivering, successively, each blank of the second set to the second location on the travel path.

In yet another of its aspects, the present invention provides a system for delivering blanks to a processing station, comprising: - an input location for providing a plurality of blanks to be processed; - a conveyor having an upstream end near the input location and a downstream end near the processing station; -a reject location for receiving rejected blanks; - a robotic arm operable to transfer blanks from the input location to the upstream end of the conveyor; - a blank pick up assembly coupled to the robot arm and having a plurality of engaging members for engaging the blank in order to deliver the blank to a 20 sensing location which is spaced from the pickup location, and at least one sensing means for sensing a normal condition and a reject condition at the sensing location; - the normal condition being defined by the presence of only a single blank at 25 the pickup assembly, wherein the robot arm is operable, in the normal condition to transfer the single blank from the sensing location to the upstream end of the conveyor; - the reject condition being defined by the presence of two or more blanks at 30 the pickup assembly, the pickup assembly further comprising at least one supplemental engagement means operable in the reject condition to engage the two or more blanks with sufficient strength to enable the robot arm to ( transfer the two or more blanks from the sensing location to the reject location and thereafter to release the two or more blanks from the pickup assembly to deliver the two or more blanks to the reject location.

In one embodiment, the engagement means includes a plurality of suction devices positioned on the pickup assembly for establishing a suction connection between the blank and the pickup assembly. The blanks are ferromagnetic and the sensing means is operable to sense changes in magnetic flux. The robotic arm has a coupling end carrying the pickup assembly, the pickup assembly further comprising a frame 10 arrangement supporting the suction devices, the sensing means being positioned in order to be immediately adjacent the blank when the robotic arm lifts the blank from the input location, in order to sense changes in flux. The supplemental engagement means, in this case, includes one or more magnets to deliver a magnetic force to the two or more blanks, but could include such things as ultrasonic sensors and the like, 15 provided they are capable to detecting a change in a wave or signal indicating the presence of one, or alternatively more than one, blank at the pick up assembly in the sensing location.

Preferably, the supplemental engagement means includes displacement means which 20 is operable in the reject condition to displacing the magnet from an inoperative position in which the magnet is spaced a sufficient distance from the blank so as to exert substantially no attraction thereon to an operative position sufficiently close to the blank so as to exert a magnet attraction force thereon.

In still another of its aspects, there is provided a method for delivering blanks to a processing station, comprising the steps of: - providing an input location for providing a plurality of blanks to be processed; providing a conveyor having an upstream end near the input location near a downstream end at the processing station; ( -providing a reject location for receiving rejected blanks; - providing a blank pickup unit; - lifting a blank from the input location with the pickup unit; - sensing for the presence of more than one blank at the pickup unit; - if a number of blanks are sensed, delivering the pickup unit to the reject location and releasing the blanks; and - if only one blank is sensed, delivering the blank to the upstream end of the conveyor.

In still another of its aspects, there is provided a method for delivering blanks to a processing station, comprising: - a step for providing an input location for providing a plurality of blanks to be processed; - a step for providing a conveyor having an upstream end near the input location and a downstream end at the processing station - a step for providing a reject location for receiving rejected blanks; 25 - a step for providing a blank pickup unit; - a step for lifting a blank from the input location with the pickup unit; - a step for sensing for the presence of more than one blank at the pickup unit; ( -if a number of blanks are sensed, a step for delivering the pickup unit to the reject location and releasing the blanks; or - if only one blank is sensed, a step for delivering the blank to the upstream end of the conveyor.

In still another of its aspects, there is provided a method for increasing the processing speed of a laser blanking line, comprising the steps of: providing two input locations for providing a source for two sets of blanks 10 in a first group; - providing a travel path having an upstream end, the travel path extending though a shearing station to a laser welding station; -providing a reject location for receiving rejected blanks; - providing a pair of blank pickup units, one adjacent each of the input locations; - lifting a blank from the input location with each pickup unit; - sensing for the presence of more than one blank at each pickup unit; - if a number of blanks are sensed, delivering the pickup unit to the reject location and releasing the blanks; - if only one blank is sensed, delivering the blank to the travel path for delivery to the shearing station - shearing one end of each of the blanks; and 30 delivering the blanks to the laser welding station along the travel path for welding together the sheared ends of the blanks to form a welded blank. (

BRIEF DESCRIPTION OF THE DRAWINGS Several preferred embodiments of the present invention will be provided, by way of example only, with reference to the appended drawings, wherein: Figure 1 is a schematic view of a portion of the welding line; Figures 2 to 5 are schematic views of a clamp assembly in the welding line of figure 10 1; Figure 6 and 7 are schematic views of two portions of the clamp assembly of figures 2 to 5; Figure 8 is a schematic plan view of a welding plant implementing the welding line of figure 1; Figure 8a is a schematic plan of shearing station of the portion of the plant of figure 8; Figure 8b is a schematic view of a laser weld station portion of the plant of figure 8, implementing the welding line of figure 1; Figure 9 is a fragmentary perspective view of a laser weld station in the plant of 25 figure 8; Figure 10 is a perspective view of a clamp portion of the weld station of figure 9; Figure 10a is a schematic view of a hydraulic ram segment of the clamp portion 30 shown in figure 9; Figure 1 1 is another perspective view of the clamp portion of figure 10; ( Figures 12 a) and b) are perspective and end views of one element of the clamp portion of figure 11; Figure 13 is a perspective view of another portion of the weld station of figure 9; Figures 14a) and b) are perspective views of another portion of the weld station of figure 9; Figures 1 5a) and b) are perspective views of still another portion of the weld station of figure 9; Figure 16 is schematic view of a controller for use with the clamp assembly; 15 Figure 16a is a schematic operational flow diagram of the clamp assembly; Figure 17 is a perspective view of a conveyor portion of the weld station of figure 9; Figures 18 a) and b) are perspective and end views of one part of the conveyor 20 portion of figure 17; Figure 19 is a perspective view of another conveyor portion of the weld station of figure 9; Figures 20 a) and b) are perspective and end views of one part of the conveyor portion of figure 19; Figures 21 and 22 are perspective views of two portions of the shearing station of figure 8a; Figure 23 is a schematic view of a controller for use with shearing station in the plant of figure 8; ( Figure 24 is a schematic operational flow diagram of the shearing station; Figures 25 and 26 are perspective views of robot stations in a delivery station portion of the welding plant of figure 9; Figure 27 is schematic view of a controller for use with delivery station of figure 9; and Figure 28 is a schematic operational flow diagram of the shearing station;

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Figure I illustrates, schematically, a portion of a weld station line shown at 6 15 including a conveyor 8 and a laser welding unit shown at 9. The welding line 6 is part of a welding plant shown in figures 8. Several other stations of the welding plant will be described below.

Referring to figures 2 to 5, the welding station includes a clamp device 10 including 20 an upstream clamp assembly 12 and a downstream clamp assembly 14, each of which is located on a travel path 16 (provided in this case by the conveyor 8). In this example, conveyor 8 is arranged to carry a thick blank 18 and a thin blank 20, in this case for the production of "tailored blanks" for the fabrication of automobile parts or other manufactured articles.

The blanks 18, 20 are formed from a ferromagnetic material, such as coated or uncoated cold rolled mild steel, stainless steel, or the like. Conveyor 8 is continuous and has a pair of is magnetized sections 8a (shown in figure 9) to hold the steel blanks during transfer. Magnetized conveyors of this type are well known in the automobile industry and are, for example, described in the Honda '469 patent. 30 Referring to figures 2 to 5, the clamp assemblies 12 and 14 respectively have mating clamp jaws 12a, 12b and 14a, 14b. In this case, the clamp assembly 12 is ( "upstream" of the clamp assembly 14 relative to the travel path 16 whose direction generally travels from left to right in figures 2 to 5. The function of each clamp assembly relates in part to its position on the travel path and will therefore also, in some cases, be hereinafter referred to as the "upstream" and "downstream" clamp 5 assemblies 12 and 14 respectively. Both are both movable to an open position as shown in figure 2. Here, the open position is defined by a spacing between the inner surfaces of the jaws which is at least sufficient to permit the thick blank to travelalong the travel path 16, through the upstream clamp assembly 12 to its position as shown in figure 2 in the downstream clamp assembly 14. 10 Further details of the downstream clamp assembly 14 are shown in figures 2, 9, 10, 11, 12a, 12b, it being understood that the upstream clamp assembly 12 is essentially identical to the downstream clamp assembly 14, except of course for its opposite orientation and its position on the travel path 16. The upper and lower clamp jaws 15 14a and 14b include an upper clamp beam 14c and a lower clamp beam 14d respectively, as shown in figure 10. In this case, a plurality of clamp elements 14e (shown in figure 2) are fastened to each of the upper clamp beam 14c by way of a nut and bolt arrangement 14f extending through a passage 14g and spring biased downwardly by way of spring 14h. As shown in figures 12a and 12b, each clamp 20 element 14e is also provided with a pair of cooling fluid passages 14i to circulate coolant through the clamp elements during the welding operation Referring to figures 10 and 11, a clamp drive unit 17, in this case including a pair of back to back hydraulic rams 17a (shown schematically in figure 1Oa) displaces the 25 upper clamp beam relative to the lower clamp between the open and closed positions. The back to back hydraulic rams 17a further include a first ram 17b which has a cylinder whose end-to-end displacement equals the clamp distance from the open position to the intermediate position. The first ram 17b is anchored to a frame 17c which is moveable under the action of a second ram 17d, the latter of which has 30 an end-to-end displacement which equals the clamp distance from the intermediate position to the closed position.

Referring to figure 11, a clamp frame assembly, generally shown at 19, supports the upper and lower clamp beams and includes a central passage 19a and a pair of lateral positioning members are located in the central passage, as will be described below.

Referring more particularly to figures 2 to 5 8b and 13, one or more locating members 26 are located between the upstream and downstream clamp assemblies.

The locating members 26 may be in the form of setting pins, stops or positioners, each driven by a locating drive assembly 27, as shown in figure 13. In this case, only one locating member is used. The locating drive assembly 27 has a carriage member 10 27a mounted for lateral travel (that is transverse to the travel path 16) on a servo positioner 27b having a pair of elongate track members 27c, a drive motor 27d which drives a linear screw drive 27e by way of a belt 27f. The carriage support supports a vertically oriented actuator 27g with an output shaft 27h coupled to the locating member by way of block 27i.

The actuator 27f is operable to move the locating member 26 between an inoperative position as shown in figure 2 to an operative position as shown in figure 3, in the latter position to locate the thick blank in a weld position beneath the location of a weld laser beam (shown schematically at 28). The weld laser 28 is provided by a 20 weld unit 28a, the details of which can be found in the Honda '469 patent. As can be seen in figure 4, the locating member 26 is movable back to its inoperative position after the thick blank is suitably positioned in its weld position and clamped therein by the downstream clamp assembly 14. It will also be seen in figure 3 that the downstream clamp assembly is moved to an intermediate position between the open 25 position of figure 1 and the closed position of figure 4.

Referring first to figures 3, 6 and then to figures 9, 14a and 14b, a first displacement unit 30 is located near the downstream clamp assembly 14 to displace the edge 18a of the thick blank to its weld position in abutment with the locating member 26. The 30 displacement unit has an abutment member 32 which is driven by a servo positioner 34. Referring to figure 14a, the abutment member includes a pair of upwardly directed flanges 32a and a blank abutment assembly 32b mounted on the flanges 32a ( by way of linear bearings 32c and tracks 32d. The blank abutment assembly includes an abutment pad 32e which is positioned adjacent a back plate 32f by bolts 32g (having a pair of spring loaded dampers. A first actuator 32h is operable to actuate the blank abutment assembly 32b between an operable position in the travel path and 5 an inoperable position below the travel path. The first actuator 32h displaces the blank abutment assembly 32b relative to a base fixture 32i, the latter of which is mounted on the carriage 34a of the servo positioner 34, shown in figure 9. The servo positioner 34 is preferable for welding systems which produce many different parts.

A welding system dedicated to one part, on the other hand, may alternatively make 1 0 use of hydraulic, electro mechanical or pneumatic displacement units.

The upstream clamp assembly 12 is movable from the open position shown in figure 2 to an intermediate position as shown in figure 3. The intermediate position is selected to constrain the thin blank 20 to pass through the upstream clamp assembly 15 12 in a substantially coplanar relationship with the thick blank 18, so that the edge 20a of the thin blank can make edge-to-edge contact with the edge 18a of the thick blank 18, but not to overlap or ride over the thick blank 18.

The upstream clamp assembly 12 is also movable from the intermediate position to a 20 closed clamped position to clamp the thin blank in its welded location, so that the welding process can proceed.

Referring to figure 11, first and second lateral positioning assemblies 36, 38 are provided, respectively, for positioning the first and second blanks relative to the 25 travel path 16. In most cases, this lateral positioning function may involve centring the thick and thin blanks on the travel path 16 or, in other cases, adjusting the position of one blank such as the thick blank, relative to the other. This would be carried out, for example, when the one of the blanks, is narrower than, and has to be aligned with a predetermined end or section of, the other blank. Each blank has a 30 pair of side edges (such as the side edges 18b of thick blank 18 in figure 11) and the lateral positioning assembly includes a pair of lateral abutment members 36a, 38a, each for engaging a corresponding side edge, and a lateral servo positioner 36b, 38b ( for positioning each of said lateral abutment members. Each of the lateral abutment members 36a, 38a includes an upwardly directed flange 36d, 38d, a number of stop members 36e, 38e mounted on the flange to abut the side edges of the blank and a number of ball transfer units 36f, 38f (the latter to support the underside of the blank).

Referring to figures 4, 7, 9 and 15a), 15b), located near the upstream clamp assembly 12 is a second displacement unit 40 to displace the edge 12a of the thin blank toward its edge-to-edge abutment with the edge 18a of the thick blank at the 10 weld location. As with the displacement unit 30, the displacement unit 40 similarly includes an abutment member 42 which is driven by a servo positioner 44. The abutment member 42 includes pair of upwardly directed flanges 42a and a blank abutment assembly 42b mounted on the flange, by way of linear bearings 42c and tracks 42d. The blank abutment assembly includes an abutment pad 42e which is 1 5 positioned adjacent a back plate 42f by bolts 42g. A second actuator unit 42h is provided for actuating the blank abutment assembly 42b between an operable position in the travel path and an inoperable position below the travel path 16. The abutment member includes a base fixture 42i which is mounted on the carriage 44a of the servo positioner 44.

Referring to figure 16, a controller 30 communicates with the conveyor 8, the longitudinal servo positioner 34, the later servo positioners 36a, 36b and the clamp drive unit 17 (for both the upstream and downstream clamp assemblies 12, 14), the longitudinal servo positioner 44 and the conveyor 8 by way of one or more 25 communication channels 31a to 31g, such as separate cables or a single communication bus, as will be understood to those of skill in the art. The controller may also have control over all of the other functions in the weld line, such as by the use of a PLC, a general purpose computer, or some other form of controller.

The general purpose computer may work within a network involving several general (it-TPO ( DITMD purpose computers, for example those sold under the trade names APPLE, or IBM; or clones thereof, which are programmed with operating systems known by the trade ( ((iT) names WINDOWS, LINUX or other well known or lesser known equivalents of these. The system involves pre-programmed software using a number of possible languages or a custom designed version of a programming software sold under the trade name ACCESSor similar programming software. The computer network may 5 be a wired local area network, or a wide area network such as the Internet, or a combination of the two, without or without added security, authentication protocols, or under "peer-to-peer" or "client-server" or other networking architectures. The network may also be a wireless network or a combination of wired and wireless networks. The wireless network may operate under frequencies such as those 10 dubbed 'radio frequency' or "RF" using protocols such as the 802.11, TCP/IP, BLUE TOOTIjand the like, or other well known Internet, wireless, satellite or cell packet protocols. The system may, alternatively, be executed on a single custom built computer which is dedicated to the function of the system alone.

Referring to figure 16a, the welding station operates as follows, it being understood that the steps discussed below are not necessary in any fixed order. Rather, some of the steps, particularly the timing of sequences provided by the controller, may be changed under different circumstances and depending on such factors as the speed of the line, the properties and shape of the thick and thin blanks, and the like. 20 First, a pair of blanks, in this case a thick blank and a thin blank, are prepared for the welding of a tailored blank. This may include, for example an upstream shearing device to provide a trailing edge on the thick blank and a leading edge on the thin blank with suitable dimensional tolerances. The thick blank is delivered to the 25 conveyor 8 at its upstream end shown at "U" in figure 1 followed by the thin blank.

The controller then adjusts the longitudinal positioners 34 and 40 as well as the lateral positioners 36, 38 for each clamp assembly 12, 14 and the locating member 26, according to the dimensions of the blanks being welded. The controller then 30 instructs the upstream and downstream clamp assemblies to be opened to the position as shown in figure 2. The controller also instructs the magnetic conveyor 8 to magnetize and thereby grip the blanks, and then to deliver the blanks to the ( clamping device 10.

The thick blank is delivered to its first location as shown in figure 3 at which time the controller instructs the locating member 26 to its operative position at the second 5 location in the travel path, also as shown in figure 3. The controller also instructs the downstream clamp to be lowered to an intermediate position The controller then instructs the displacement unit 30 to move the thick blank, until its edge 1 8a abuts the locating member 26 at the third location. The lateral 10 positioning assemblies 36 and 38 are then instructed by the controller to position the blank in its proper side-to-side orientation, that is essentially parallel to the path of travel of the laser beam during welding and essentially in a position to be in line with the approaching thin blank. The controller then instructs the downstream clamp assembly to move to its closed clamping position and the locating member 26 to 15 retract to its inoperative position as shown in figure 4.

The controller then instructs the upstream clamp assembly to move to its intermediate position, as shown in figure 4.

The timing of the retraction of the locating member 26 is set to occur just before the thin blank arrives in the upstream clamp assembly.

The controller then instructs the displacement unit 40 to move the thin blank until its edge 1 2a comes to the fourth location in edge-to-edge contact with the trailing edge 25 18a. The lateral positioning assemblies and are then instructed by the controller to position the thin blank in its proper side to side orientation, that is essentially parallel to the path of travel of the laser beam during welding and essentially in an in line position with the thick blank. The controller then instructs the upstream clamp assembly to move to its closed clamping position to clamp the thin blank in the 30 fourth location.

Thus, the clearance of the upstream clamp assembly in its intermediate position is ( selected to permit the thin blank to travel through the clamp at a faster speed to bring collision. However, the intermediate position is such that the thin blank is unable to be deflected to ride over the trailing edge of the thick blank.

The controller then instructs the laser welding unit to initiate the weld by delivering the laser beam 28 to the weld location.

While the above device is arranged to clamp blanks of unequal thickness to form a tailored blank, it will be understood that the device may also be configured to weld 10 blanks of substantially equal thickness. The thick blank, in the above arrangement, need not necessarily be delivered first to the downstream clamp assembly in all possible situations, but instead may in some cases follow the thin blank. Thus, the clearance in the upstream clamp may not be smaller in the intermediate position than the open position in all cases.

Referring now to figures 8, 8a, and 17 to 24 the welding line has a shearing station 50 upstream of the welding station 9. Details of the shearing station 50 can be found in the Honda '469 patent. The welding plant also includes a conveyor system 60 for delivering, successively, two groups of blanks of different dimensions along a travel 20 path (or two travel paths) to the shearing station 50 and for orienting each blank to arrive at the station in a precisely controlled orientation.

The conveyor system 60 includes continuous magnetic conveyors 62 and 64 on either side of the shearing station 50 and a conveyor 65 downstream of conveyor 64. 25 Conveyor 8 is downstream of conveyor 65 and presents the welded tailored blank to a pick up station 'P', the details of which can be seen in the Honda '469 patent.

Conveyor 62 has an upstream end 62a where it receives thin blanks as will be described and a downstream end 62b where the thin blanks are delivered to the shearing station 50. As will be described, conveyor 64 has a first end 64a, as shown 30 in figure 8. Both conveyors 62 and 64 operate in two different directions in different operating phases as will be described. In one phase, for example, the blanks which are deposited on the conveyor are then delivered one-by-one, to the shearing station ( 50. In another phase, the thick and thin blades are both transferred by the conveyor, together (or in pairs) from the first end 64a to the welding station 9. Each conveyor delivers a blank to a respective side of the shearing station. The conveyor 62 delivers, in this case, the thin blank to the upstream side of the shearing station (that 5 is the left side as viewed in figure 8) while the conveyor 64 delivers the thick blank to the downstream side of the shearing station 50 (that is the right side as viewed in figure 8).

A pair of lateral positioning arms 66, are located adjacent the downstream end 62b 10 of the conveyor 62 to align the thin blank laterally, relative to the shearing station.

Similarly, a pair of lateral positioning arms 68 are also located adjacent the upstream end 64a of the conveyor 64 to align the thick blank.

Each of the lateral positioning arms 66, 68 engages and positions one side edge of a 15 corresponding thin blank or thick blank and is incrementally driven by servo positioners 66a, 68a respectively (as seen in figures 21, 22). Each of the lateral positioning arms respectively includes an upwardly directed frame member 66b, 68b and a plurality of stop members 66c, 68c mounted on the frame member. Located adjacent the stop members are a number of ball transfer units 66d, 68d. The transfer 20 units mounted on a frame 66e, 68e and are movable relative to the frame member 66b, 68b to adjust the point of support of the blanks, depending on their size, under the action of actuators 66f, 68f. Blanks 18 and 20 are shown in figures 22 and 21, respectively, each in an engaged position with the lateral positioning arm.

The servo positioners 66a, 66b are movable between an inoperative position and an operative blank-engaged position, wherein the blank- engaged position is selected to locate each blank of the first group in a precisely controlled first orientation and each blank of the second group in a precisely controlled second orientation. In other words, in the operative position, the stop members are spaced from the side edges of 30 the blank, while the blank is travelling over and is supported on its underside by the ball transfer units 66d, 68d. (

Referring to figures 17 to 20b, a pair of longitudinal positioning assemblies 100 and 101 are provided for positioning either a leading edge or a trailing edge on the two blanks.

Referring to figure 1 8a, the longitudinal positioning assembly 100 has a carriage 102 mounted for travel along the travel path by way of a servo positioner 104, two setting pins 106 and two drive units 108 for driving the setting pins between an operative position interrupting the travel path and an inoperable position below the travel path (the former position shown in dashed lines and the latter position shown 10 in solid lines, both in figure 18b). The setting pins 106 are located at a position in the travel path to engage the trailing edge 20b of the thin blank (as seen in figure 17).

Referring to figure 20a, the longitudinal positioning assembly 101 similarly has a 15 carriage 120 mounted for travel along the travel path by way of a servo positioner 121. Two setting pins 122, driven by two drive units 124, are movable between an operative position interrupting the travel path (as shown in dashed lines in figure 20b) and an inoperable position below the travel path (as shown in solid lines in figure 20b). The setting pins are located at a position in the travel path to engage, in 20 this case, the leading edge of the blank.

In this case, the servo positioners 104, 121 are used to adjust the otherwise longitudinally stationary positions of the setting pins 106, 122 relative to the travel path during processing of the blanks. The servo positioners provide the benefit that 25 the shearing station can, very efficiently, be adjusted to accommodate a part change, without the need for manual adjustments.

Referring to figure 23, a servo controller 126 is also provided for controlling the servo positioners 66a, 68a, 104, and 121, as well as the drive units 108 and 124 and 30 the conveyors 62, 64 and 65, by way of conductors 127a to 127j. The controller 126 may of the type described above for controller 30 and is functionally integrated therewith. (

Referring now to the flow diagram of figure 24, the conveyor system 60 is used as follows. The first group of blanks in this specific example is a set of thin blanks to arrive on the conveyor 62 and a set of thick blanks to arrive on the conveyor 64. The 5 thick and thin blanks of the first groups are matched with one another according to some predetermined parameter. For example, they might both be used in the fabrication of a tailored blank for a door component. In this case, data is entered into the controller to define the thin and thick blanks of the first group. The controller 126 then actuates the servo positioners 104, 121 to adjust the position of the setting 10 pins 106, 122 according to the dimensions of the thin and thick blanks, in this case.

Once the position has been set, the setting pins 106, 122 will remain stationary along the travel path during the processing of the first group of blanks, but will shuttle vertically between an operative position in the travel path and an inoperative position below the travel path 16. Similarly, the controller actuates the servo 15 positioners 66a, 68a according to the dimensions of the blanks in this case. The servo positioners will have a memory position corresponding to the width of the respective blocks and the controller is operable to shuttle the stop members 66c, 68c between an open position and the memory position.

After one thin blank is delivered to the conveyor 62, the controller instructs the drive units 108 to actuate the pins 106 to their operative position in the travel path. The conveyor travels in reverse (that is opposite to the direction of travel path 16) to displace the thin blank upstream to bring the trailing edge of the blank against the pins 106. The controller then instructs the magnetic conveyor to reverse direction 25 (again) and deliver the thin blank into the region of the lateral positioners 66, which are then instructed by the controller to engage the side edges of the blank and align it laterally relative to the shearing station.

Similarly, after one thick blank is delivered to the conveyor 64, the controller 30 instructs the drive units 124 to actuate the pins 122 to their operative position in the travel path. The conveyor then displaces the thick blank downstream to bring the leading edge of the blank against the pins 122. The controller then instructs the ( magnetic conveyor to reverse its direction (that is opposite to the direction of travel path 16) and deliver the thick blank into the region of the lateral positioners, which are instructed by the controller to engage the side edges of the blank and align it laterally relative to the shearing station. The shearing station then shears the adjacent 5 ends of the thin and thick blanks simultaneously (as disclosed in the Honda '469 patent). After shearing, the thick and think blanks are carried by conveyor 64 to the welding station. Meanwhile, the shearing operation is repeated for another pair of blanks from the first group until the thin and thick blanks of the first group have been processed.

The conveyor system 60 may then be prepared for a second group of blanks. Again, using the same specific example, the second group is a set of thin blanks to arrive on the conveyor 62 and a set of thick blanks to arrive on the conveyor 64. The thick and thin blanks of the second group are matched with one another according to some 15 predetermined parameter, such as a truck hood and is thus different from the first group. In this case, the data is entered into the controller to define the thin and thick blanks of the second group. As a result, the controller and the servo positioners are able to adjust automatically for the different dimensions of the second group without the need for manual changes, such as the removal of one set of dedicated jigs on the 20 lateral positioners for the first group and the installation of a second group of jigs for the second group.

Thus, the controller 126 is operative in: - a first phase to adjust the operative and inoperative positions according to the dimensions of the blanks in the first group, - a second phase to shuttle the first and second servo positioners between their inoperative and operative positions as the blanks in the 30 first group are being processed; - a third phase to adjust the operative and inoperative positions ( according to the dimensions of the blanks in the second group; and - a fourth phase to shuttle the first and second servo positioners between their inoperative and operative positions as the blanks in the second group are processed.

Referring to figures 8 and figures 25 to 28, the welding line is also equipped with a delivery station 200 for delivering blanks to the conveyor 62, in one case upstream of the shearing station 50 and, in another case, downstream thereof (relative to the 10 direction of the travel path 16) . The delivery system includes an input location 204 for providing a plurality of blanks to be processed. In this case, the input location has a pair of bulk blank carrying hoppers 204a, 204b. The hoppers may also be provided with blank fanning units as are known to separate, at least partially, the uppermost blank from the remaining stack of blanks. The conveyor 60 has an 15 upstream end 62a near the input location and a downstream end 62b at the shearing station. A reject location for receiving rejected blanks is provided at 210 and, in this case, includes a reject receiving bin 210a.

A robotic arm is provided at 220 and is operable to transfer thin blanks from the 20 input location 204 to the upstream end 60a of the conveyor. A similar robotic arm is provided at 230 and is equipped to handle the thick blanks. In this case a second input location is provided at 232 with similar hoppers 232a and 232b. In this case, the robotic arm 230 transfers thick blanks to the conveyor 64 to deliver them to the sheering station at 50.

Referring to figure 25, the robot arm 220 has a coupling end 222 which carries carrying a blank pick up assembly 240 which itself includes a frame arrangement 242 formed by a pair of elongate frame members 242a and a number of cross members 242b. The latter cross members support a plurality of engaging members in 30 the form of suction devices 244, which are positioned on the pickup assembly for establishing a suction connection between the blank and the pickup assembly, in order that the suction devices can, collectively, deliver sufficient upward force to ( stick' the blank temporarily against the frame arrangement so that the pickup assembly can lift the blank. The suction devices may be replaced by other pickup devices, such as magnets and the like. In this case, the suction devices are supplied by a number of suction lines, one of which is shown in dashed lines at 244a, 5 operated by valves, one of which is shown at 244b. Each of the suction devices are provided on a spring loaded arm 244c which permit the pick up assembly to establish initial contact between the suction devices and the uppermost blank and then to press the suction device further under the action of each spring loaded arm 244c while the vacuum is being established each suction device. 10 The cross members also carry one or more sensing means in the form of magnetic flux sensors (in this case only one such sensor is shown at 246) which are operable to sense changes in magnetic flux. These changes will vary depending on whether one or more than one blanks is adjacent the sensor. The sensor 246 is positioned to 15 be immediately adjacent the blank when the robotic arm lifts the blank from the input location. The sensor is operable, after the blank has been lifted a short distance off the stack of blanks (such as for example in the order of about I to about 5 cm) to sense a normal condition and a reject condition. An example of the sensor 246 is available from SYRON.

The normal condition occurs when the sensor senses the presence of only a single blank at the pickup assembly. The robot arm is operable, in the normal condition, to transfer the sensed single blank to the conveyor 62.

The reject condition occurs when the sensor senses the presence of two or more blanks at the pickup assembly. In this case, the pickup assembly is further provided with at least one supplemental engagement means, in this case a plurality of magnets, one of which is shown at 248. The magnet 248 is operable in the reject condition to deliver a magnetic attraction force to the two or more blanks operable to 30 engage the two or more blanks with sufficient strength to permit the robot arm to pick up the two or more blanks. In this case, the magnet 248 is located on a spring loaded arm 249. The spring loaded arm 249 thus brings the magnet into contact with ( the uppermost blank as the suction devices, so that, in the case oftwo or more blanks being detected in the reject condition, the magnet will anchor them against the pickup assembly. The magnet 248 may be a rare earth magnet, for example.

Alternatively, the magnets may be electromagnetic so that they can be activated only 5 when needed. In addition, the magnets may be displaced from an inoperative position to which is operable in the reject condition to displace the magnet from an inoperative position in which the magnet is spaced a sufficient distance from the blank so as to exert substantially no attraction thereon to an operative position sufficiently close to the blank so as to exert a magnet attraction force thereon. 10 Thus, the robot arm is operable, in the reject condition, to actuate the magnets and thereafter to transfer the two or more blanks to the reject receiving bin. The suction devices and the magnets are then operable at the reject location to release the two or more blanks from the pickup assembly.

The delivery station 200 is controlled by a controller 250 which is of the type described for controller 30 and is functionally integrated with the controllers 126 and 30 as described above. The controller 250 controls the valves 244a, the solenoid actuator 249 driving the magnet 248 and, generally, the various functions of the 20 robot 220 by way of communication channels 252a to 252c. The controller also controls the equivalent components of the robot 230.

Referring to figure 28, the delivery system thus operates as follows. The robotic arm is directed to the input location 204 and the pickup assembly is lowered until the 25 suction devices 244 and the magnet 248 contact the uppermost blank on the stack of one of the blank carrying hoppers. The suction devices are activated and a suction force is delivered to the uppermost blank. The robot then lifts the pickup assembly, thereby causing the uppermost blank to be lifted off the stack. After the robot has lifted the blank a short distance above the stack, the sensor is activated. If it detects 30 only a single blank, then the robot is directed to transfer the single blank to the upstream end 62a of the conveyor 62. (

On the other hand, if the sensor detects more than one blank, the magnets 248 are in contact with the uppermost blank and holds the multiple blanks in a bundle against the pickup assembly and the robot is then directed to deliver the bundle to the reject receiving bin where the suction devices are then inactivated to release the bundle 5 from the pick up assembly. In this case, the magnetic force is insufficient to overcome the vacuum decoupling between the suction devices and the uppermost blank. As a result, both blanks are released.

The robot arm 232 operates in the same manner by way of its suction devices 250, 10 sensor 252 and magnets 254 and, in this example, delivers the bundles of thick blanks to the same reject receiving bin.

Thus, the robot is, in this instance, capable of monitoring the presence of a double blank during the initial moments immediately after the positive engagement of the 1 5 uppermost blank with the pick up assembly and after the instant that the uppermost blank is separated from the remaining blanks at the input location, for example in the order of about 0.1 to 0.5 seconds, following initial displacement of the uppermost blank. Alternatively, the sensing function may be triggered by a spacing limit between the engaged blank and the topmost blank remaining at the input location. 20 This distance may be in the order of about I to about 5 cm, though different spacings may be equally applicable depending on the orientation of the input location the conveyor, the reject location and, of course, the robot arm itself.

The method of detecting a double blank is beneficial because the detection function 25 can occur during transfer and the robot can be diverted to the reject location instead of the conveyor when a double blank is detected. The method provides the advantage of combining the two functions of detection and transfer into one continuous operation. The shearing station, in this particular example, will only be interrupted for a relatively short time while the reject function proceeds and another 30 single blank is detected.

While the present invention has been described for what are presently considered the preferred embodiments, the invention is not so limited. To the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions. (

Further particular and preferred aspects of the invention are set out in the accompanying independent and dependent clauses. Features of the dependent clauses may be combined with those of the independent clauses and independent claims as 5 appropriate and in combinations other than those explicitly set out in the clauses and claims.

CLAUSES: 1. A laser welding system, comprising: - a travel path to carry a first blank and a second blank, the first blank having a first weld surface and the second blank having a second weld surface, the first and second blanks being ready to be welded together to form a weld 15 seam along the first and second weld surfaces; - an upstream clamp assembly and a downstream clamp assembly positioned on the travel path; - each of the upstream and downstream clamp assemblies being movable to an open position to allow the first blank to pass through the upstream clamp assembly to a first location within the downstream clamp assembly; - a laser welding source directed at a weld location on the travel path between 25 the upstream and downstream clamp assemblies; - at least one locating means operable to locate the first weld edge adjacent the weld location; - first displacement means to displace the first weld edge against the locating means; ( - the downstream clamp assembly being movable from the open position to a closed clamped position to clamp the first blank with the first weld edge adjacent the weld location; - the locating means being operable to be withdrawn from the travel path; - the upstream clamp assembly being movable from the open position to an intermediate position, which is selected to guide the second blank to pass through the upstream clamp assembly in a substantially coplanar relationship 10 with the first blank so that the second weld edge makes contact with, but not past, the first weld edge; - second displacement means to displace the second blank to a location adjacent the weld location where the second weld edge abuts the first weld 1 5 edge; - the upstream clamp assembly being movable from the intermediate position to a closed clamped position to clamp the second blank; - the laser welding unit operable to fuse the first and second weld edges blanks together.

2. A system as defined in clause 1, further comprising first and second lateral positioning means for respectively positioning the first and second blanks 25 relative to the travel path.

3. A system as defined in clause 2 wherein each blank has a pair of side edges, each lateral positioning means includes a pair of lateral abutment members, each for engaging a corresponding side edge, and a lateral servo positioner 30 for positioning each lateral abutment member.

4. A system as defined in clause 3, further comprising lateral control means for ( incrementally controlling the lateral servo positioners.

5. A system as defined in clause 4 wherein each of the lateral abutment members includes an upwardly directed flange and a plurality of stop members mounted on the flange.

6. A system as defined in any preceding clause wherein each of the clamp assemblies includes an upper clamp beam and a lower clamp beam, a plurality of clamp elements fastened to the upper beam and a clamp drive 10 unit for displacing the upper clamp beam relative to the lower clamp between the open and closed positions.

7. A system as defined in any preceding clause wherein the first displacement means includes at least one first engagement portion for engaging the first 15 blank and a first drive portion for driving the first engagement portion.

8. A system as defined in clause 7 wherein the first engagement portion includes a first engagement member for engaging an edge on the first blank opposite the first weld edge and the first drive portion includes a first servo 20 positioner which is aligned for movement along the travel path for displacing the first engagement member; and first control means for incrementally controlling the first servo positioner.

9. A system as defined in clause 8 wherein the first engagement member 25 includes an upwardly directed flange and a blank abutment member mounted on the flange.

10. A system as defined in clause 9, further comprising a first actuator unit for actuating the blank abutment member between an operable position in the 30 travel path and an inoperable position below the travel path.

11. A system as defined in any preceding clause wherein the second ( displacement means includes at least one second engagement portion for engaging the second blank and a second drive portion for driving the second engagement portion.

12. A system as defined in clause 11 wherein the second engagement portion includes a second engagement member for engaging an edge of the second blank opposite the second weld edge and the second drive portion includes a second servo positioner which is aligned for movement along the travel path for displacing the second engagement member; and second control means for 10 incrementally controlling the second servo positioner.

13. A system as defined in clause 12 wherein the second engagement member includes an upwardly directed flange and a blank abutment member mounted on the flange.

14. A system as defined in clause 13, further comprising a second actuator unit for actuating the blank abutment member between an operable position in the travel path and an inoperable position below the travel path.

15. A system as defined in any preceding clause wherein the locating means includes a locating member movable between an operable position in the travel path and an inoperable position below the travel path and a locating drive assembly for driving the locating member between the operative and inoperative positions.

16. A system as defined in clause 15, wherein the locating drive assembly further comprises a carriage member mounted for lateral movement relative to the travel path on a third servo positioner, the carriage supporting a vertically oriented actuator with an output shaft coupled to the locating member, and 30 third control means for incrementally controlling the third servo positioner.

17. A method of welding a pair of blanks, comprising: ( - a step for providing a travel path to carry a first blank and a second blank; - a step for providing an upstream clamp assembly and a downstream clamp assembly positioned on the travel path; - a step for opening the upstream and downstream clamp assemblies; - a step for conveying a first blank along the travel path and through the 10 upstream clamp assembly to the downstream clamp assembly; - a step for positioning a laser welding unit at a weld location between the upstream and downstream clamp assemblies; a step for interrupting the travel path at the weld location with at least one blank locator; - a step for displacing the first blank until its trailing to-be-welded edge abuts the locator; - a step for clamping the downstream clamp assembly to clamp the first blank in its position against the locator; - a step for withdrawing the locator from the travel path; 25 - a step for moving the upstream clamp assembly to an intermediate position; - a step for conveying a second blank along the travel path to the upstream clamp assembly; - a step for displacing the second blank until its leading to-be-welded edge makes edge-to-edge contact with, but does not pass over, the trailing to-be- ( welded edge of the first blank; - a step for closing the upstream clamp assembly; and -a step for operating the laser welding unit to form a weld seam along the abutting edges of the first and second blanks.

18. A method for delivering, successively, two groups of blanks of different dimensions along a travel path to a downstream processing station and for 10 orienting each blank to arrive at the station in a precisely controlled orientation, each group of blanks having two sets of common blanks, comprising: - providing a conveyor arrangement to convey the blanks along a travel path; 15 - providing a first pair of lateral positioning arms on opposite sides of the travel path at a first location; - providing a second pair of lateral positioning arms on opposite sides of the 20 travel path at a second location; - incrementally controlling the position of each of the arms by a servo positioner; - processing the blanks of the first group by: - presetting the parameters of the servo positioner to define an inoperative position for each arm and an operative position wherein, in the operative position, the arms engage opposing side edge of a 30 corresponding blank to locate the corresponding blank of the first group in a precisely controlled orientation; ( - delivering, successively, each blank of the first set to the first location on the travel path; - delivering, successively, each blank of the second set to the second location on the travel path; - processing the blanks of the second group by; - presetting the parameters of the servo positioner to define an 10 inoperative position for each arm and an operative position wherein, in the operative position, the arms engage opposing side edge of a corresponding blank to locate the corresponding blank of the second group in a precisely controlled orientation; - delivering, successively, each blank of the first set to the first location on the travel path; and - delivering, successively, each blank of the second set to the second location on the travel path.

19. A system for delivering blanks to a processing station, comprising: an input location for providing a plurality of blanks to be processed; - a conveyor having an upstream end near the input location and a downstream end near the processing station; -a reject location for receiving rejected blanks; - a robotic arm operable to transfer blanks from the input location to the upstream end of the conveyor; ( - a blank pick up assembly coupled to the robot arm and having a plurality of engaging members for engaging the blank in order to deliver the blank to a sensing location which is spaced from the pickup location, and at least one sensing means for sensing a normal condition and a reject condition at the sensing location; - the normal condition being defined by the presence of only a single blank at the pickup assembly, wherein the robot arm is operable, in the normal condition to transfer the single blank from the sensing location to the 10 upstream end of the conveyor; - the reject condition being defined by the presence of two or more blanks at the pickup assembly, the pickup assembly further comprising at least one supplemental engagement means operable in the reject condition to engage 15 the two or more blanks with sufficient strength to enable the robot arm to transfer the two or more blanks from the sensing location to the reject location and thereafter to release the two or more blanks from the pickup assembly to deliver the two or more blanks to the reject location.

20. A system as defined in clause 19 wherein the engagement means includes a plurality of suction devices positioned on the pickup assembly for establishing a suction connection between the blank and the pickup assembly.

21. A system as defined in clause 20 wherein the blanks are ferromagnetic, the sensing means is operable to sense changes in magnetic flux.

22. A system as defined in clause 21 wherein the robotic arm has a coupling end carrying the pickup assembly, the pickup assembly further comprising a 30 frame arrangement supporting the suction devices, the sensing means being positioned in order to be immediately adjacent the blank when the robotic arm lifts the blank from the input location, in order to sense changes in flux. (

23. A system as defined in clause 22 wherein the supplemental engagement means includes one or more magnets to deliver a magnetic force to the two or more blanks.

24. A system as defined in clause 23, wherein the supplemental engagement means includes displacement means which is operable in the reject condition to displacing the magnet from an inoperative position in which the magnet is spaced a sufficient distance from the blank so as to exert substantially no 10 attraction thereon to an operative position sufficiently close to the blank so as to exert a magnet attraction force thereon.

25. A method for delivering blanks to a processing station, comprising the steps of: - providing an input location for providing a plurality of blanks to be processed; - providing a conveyor having an upstream end near the input location near a 20 downstream end at the processing station; -providing a reject location for receiving rejected blanks; - providing a blank pickup unit; 25 - lifting a blank from the input location with the pickup unit; - sensing for the presence of more than one blank at the pickup unit; - if a number of blanks are sensed, delivering the pickup unit to the reject location and releasing the blanks; and ( - if only one blank is sensed, delivering the blank to the upstream end of the conveyor.

26. A method for increasing the processing speed of a laser blanking line, comprising the steps of: - providing two input locations for providing a source for two sets of blanks in a first group; 10 - providing a travel path having an upstream end, the travel path extending though a shearing station to a laser welding station; -providing a reject location for receiving rejected blanks; - providing a pair of blank pickup units, one adjacent each of the input locations; - lifting a blank from the input location with each pickup unit; - sensing for the presence of more than one blank at each pickup unit; - if a number of blanks are sensed, delivering the pickup unit to the reject location and releasing the blanks; - if only one blank is sensed, delivering the blank to the travel path for delivery to the shearing station - shearing one end of each of the blanks; and - delivering the blanks to the laser welding station along the travel path for welding together the sheared ends of the blanks to form a welded blank. (

Claims

CLAIMS:

I. A conveyor system for delivering, successively, two groups of blanks of 5 different dimensions along a travel path to a downstream processing station and for orienting each blank to arrive at the station in a precisely controlled orientation, comprising: - a continuous magnetic conveyor; - first and second lateral positioning arms, each for positioning one corresponding side edge of each blank, each of the lateral positioning arms being incrementally driven by first and second servo positioners respectively; - the first and second servo positioners being movable between an inoperative position and an operative blank-engaged position, wherein the blank-engaged position is selected to locate each blank of the first group in a precisely controlled first orientation and each blank of the second group in a precisely controlled second orientation;

20 - a longitudinal positioning assembly operable for positioning either a leading edge or a trailing edge on the blank, said longitudinal positioning assembly being incrementally driven by a third servo positioner; - servo control means for controlling the first, second and third servo positioners, said control means being operative in: - a first phase to adjust the operative and inoperative positions according to the dimensions of the blanks in the first group, 30 - a second phase to shuttle the first and second servo positioners between their inoperative and operative positions; ( - a third phase to adjust the operative and inoperative positions according to the dimensions of the blanks in the second group; and - a fourth phase to shuttle the first and second servo positioners between their inoperative and operative positions.
2. A conveyor system as defined in claim I wherein each of the lateral positioning arms includes an upwardly directed frame member and a plurality 10 of stop members mounted on the frame member.
3. A conveyor system as defined in claim 2 wherein the magnetic conveyor has a travel path, the longitudinal positioning assembly further comprising a carriage mounted for travel along the travel path, a plurality of setting pins 1 5 and one or more drive units for driving the setting pins between an operative position interrupting the travel path and an inoperable position below the travel path.
4. A conveyor system as defined in claim 3 wherein the setting pins are located 20 at a position in the travel path to engage the trailing edge of the blank.
5. A conveyor system for delivering, successively, two groups of blanks substantially as described herein with reference to the accompanying drawings.