WO1999007493A1

WO1999007493A1 - Assembly machine

Info

Publication number: WO1999007493A1
Application number: PCT/US1998/010556
Authority: WO
Inventors: Dimitry Grabbe
Original assignee: The Whitaker Corporation
Priority date: 1997-08-06
Filing date: 1998-05-22
Publication date: 1999-02-18

Abstract

The present invention is directed to an assembly machine adapted for performing fabrication operations on a plurality of components prior to insertion of the components into a corresponding housing (100). The assembly machine includes a housing comprising a plurality of walls and a drive assembly that is operatively supported by the housing. A first reciprocating mechanism (304) is supported by the housing and is motivated by the drive assembly so as to provide reciprocating motion, in a first operating direction, to a first tooling module. A second reciprocating mechanism (306) is also supported by the housing and is motivated by the drive assembly so as to provide reciprocating motion, in a second operating direction, to a second tooling module. The reciprocating motions generated by the first and second reciprocating mechanisms are synchronized according to a sinusoidal relationship so as to allow fabrication operations (e.g., forming, coining, bending, etc.) to be performed on the components in synchronized relation with the insertion of the components into the cavities of the housings.

Description

ASSEMBLY MACHINE

Field Of The Invention

The present invention generally relates to automated assembly machines adapted for inserting components into corresponding housings, and more particularly to such automated assembly machines that also perform secondary operations upon the components.

Background Of The Invention

It is well known to manufacture metal components in a partially completed form so that they are more suitable for intermediate manufacturing operations, e.g., reeling, degreasing or electroplating. Once these intermediate operations are completed, final coining, forming or bending operations may be carried out on the components in order to complete their manufacture. The completed components are then transferred to an assembly machine where they are stitched into corresponding housings. Machines for assembling components into housings are well known in the art.

Significant manufacturing cost savings may be realized through the utilization of assembly machines that combine the coining, forming or bending operations with the assembly of the components into a housing.

Although such machines are known in the prior art, they have often been very costly to manufacture and operate. In many cases, such prior art machines have had great difficulty in synchronizing the coining, forming, or bending operations with the insertion of the components into the housing. Often, prior art assembly machines that incorporate coining, forming or bending stations fail to provide the necessary accuracy and precision required for many small components, and are either very expensive or are not readily retooled for different components. As a consequence, there has been a need for an assembly machine that provides the capability of both forming, blanking, and/or coining components and insertion of those components into a corresponding housing in a synchronized manner, and utilizing standard, prefabricated tooling modules.

Summary Of The Invention

The present invention provides an assembly machine adapted for performing fabrication operations on one or a plurality of components prior to insertion of the components into cavities defined within a corresponding housing. The assembly machine comprises a housing comprising a plurality of walls and a drive assembly that is operatively supported by the housing. A first reciprocating mechanism is supported by the housing and is motivated by the drive assembly so as to provide reciprocating motion, in a first operating direction, to a first tooling module. A second reciprocating mechanism is also supported by the housing and is motivated by the drive assembly so as to provide reciprocating motion, in a second operating direction, to a second tooling module. The reciprocating motions generated by the first and second reciprocating mechanisms are synchronized according to a sinusoidal relationship so as to allow fabrication operations (e.g., forming, coining, bending, etc.) to be performed on the components in synchronized relation with the insertion of the components into the cavities of corresponding housings.

In one preferred form of the invention, the drive assembly includes a drive shaft and a driven shaft each being rotatably supported by the walls defining the housing. The drive shaft is positioned in rotatable engagement with the driven shaft and includes a first end that is rotatably engaged by a motor. The first reciprocating mechanism includes a main connecting rod comprising a receptacle end and a coupling end. The receptacle end has a portion of the driven shaft eccentrically mounted therein so that the main connecting rod is reciprocatingly driven in response to rotative movement of the driven shaft. The coupling end is disposed in driving engagement with the first tooling module whereby motive force is provided for reciprocally actuating the first tooling module. The second reciprocating mechanism includes a multicrank assembly supported by the walls that define the housing, and is rotatably engaged by a second end of the drive shaft. A first eccentrically mounted crank drivingly engages a hitch feed so as to synchronously move the components into the first and second tooling modules. A second and a third crank are eccentrically mounted with the first eccentrically mounted crank. The second and third cranks each have an arm that actuatingly engages the second tooling module so as to synchronously and reciprocatingly drive the second tooling module into manipulative engagement with a portion of the components .

Brief Description Of The Drawings

These and other features and advantages of the present invention will be more fully disclosed in, or rendered obvious by, the following detailed description of the preferred embodiment of the invention, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:

Fig. l is an elevational side view, partially in section and partially in phantom, of the assembly machine of the present invention;

Fig. 2 is a top view of the assembly machine illustrated in Fig. 1;

Fig. 3 is a bottom view of the assembly machine illustrated in Fig. 1;

Fig. 4 is an elevational view of a main connecting rod; Fig. 5 is a side view of the main connecting rod illustrated in Fig. 4;

Fig. 6 is an elevational view of an eccentric arbor; Fig. 7 is a side view of the eccentric arbor shown in Fig. 6;

Fig. 8 is a front elevational view of the assembly machine illustrated in Fig. 1, showing portions of a multicrank assembly; Fig. 9 is a front view of a main body of the multicrank assembly shown in Fig. 8;

Fig. 10 is a side view of the main body shown in Fig. 9;

Fig. 11 is a front elevational view of a first crank;

Fig. 12 is a front view of a second crank;

Fig. 13 is a front view of a third crank or quill driver; and

Fig. 14 is a side view of a tooling module, strip of components, and a quill.

Detailed Description Of The Preferred Embodiment

Referring to Fig. 1, assembly machine 5 comprises a protective housing 100 that houses and structurally supports a drive assembly 200, a multicrank assembly 300, and a tooling module 400. More particularly, housing 100 is formed from a cast metal and comprises an outer shape that resembles a conventional sewing machine housing. Housing 100 is adapted for mounting upon a stationary portion of a programmable X-Y table (not shown) of the type that is well known in the art. Preferably, the programmable X-Y table is adapted for accurately and precisely positioning housings (not shown) below multicrank assembly 300 for stitching of components 10 by assembly machine 5. The walls comprising housing 100 are of a thickness and cross - section that are sufficient to support drive assembly 200, multicrank assembly 300, and tooling module 400. The walls of housing 100 define a drive chamber 110, a shaft chamber 115, a crank chamber 120, and a base chamber 125. Each of these chambers is sized so as to house drive assembly 200, multicrank assembly 300, and tooling module 400, respectively.

Drive assembly 200 comprises a drive shaft 205, a driven shaft 210, a main connecting rod 220, and a pulley 225. More particularly, drive shaft 205 comprises an elongate metal rod having a first end portion 230, a second end portion 235, and a central portion 240 that is disposed therebetween. Drive shaft 205 is rotatably mounted within housing 100 so as to extend substantially horizontally through drive chamber 110, shaft chamber 115 and into a portion of crank chamber 120 (Fig. 1). Conventional bearings 245, that are located within the walls that define the vertical sides of drive chamber 110 and shaft chamber 115, support drive shaft 205. Pulley 225 is mounted to first end portion 230 of drive shaft 205 and is adapted to be engaged by a flexible transmission system, such as a belt, so as to provide motive force to assembly machine 5 via a conventional motor (not shown) . A conventional shaft encoder and clutch-brake mechanism or a servo motor 227 is also mounted to first end portion 230.

Shaft encoder 227 is of the type that is well known in the art for determining the positional orientation of a rotating shaft such as drive shaft 205 as its rotation is started and stopped during operation of assembly machine 5. The conventional clutch mechanism allows for braking and releasing of drive shaft 205 as various operations are carried out by assembly machine 5. A first spiral gear 247 is annularly mounted on drive shaft 205, adjacent to central portion 240, so as to be positioned within drive chamber 110.

Driven shaft 210 comprises a metal rod having a first end portion 250 and a second end portion 253. First end portion 250 is centrally disposed within drive chamber 110. The remainder of driven shaft 210 extends into base chamber 125, via a central bore 256 defined within lower wall 258 of drive chamber 110. Conventional bearings 245 also support driven shaft 210 within wall 258. A second spiral gear 260 is annularly mounted on first end portion 250 so as to be disposed in enmeshed engagement with first spiral gear 247. In this way, rotational motive force may be applied to driven shaft 210, by drive shaft 205, during operation of assembly machine 5. A main counter weight 263 and a balancing counter weight 265 are annularly mounted upon driven shaft 210, between second spiral gear 260 and lower wall 258, so as to reduce vibrations during operation as is well known in the art. An arbor 267

(Figs. 3, 6 and 7) is mounted in annular relationship to second end portion 253 of driven shaft 210. Arbor 267 comprises a base portion 269 having an eccentrically positioned bore 271 defined therethrough. Bore 271 is sized and shaped so as to slidingly receive second end portion 253 of driven shaft 210 so that driven shaft 210 may be securely fastened to arbor 267.

Referring to Figs. 1, 3, 4 and 5, main connecting rod 220 comprises an arbor receptacle 273 formed at a first end and a coupling bracket 275 formed at a second end. More particularly, arbor receptacle 273 comprises an annular structure that defines a bore 274 extending through main connecting rod 220. The diameter of bore 274 is sized so as to receive base portion 269 of arbor 267. Arbor receptacle 273 is sized and shaped so as to fit within base chamber 125 of housing 100. Main connecting rod 220 projects outwardly from base chamber 125, toward tooling module 400, in substantially parallel relation to drive shaft 205. Coupling bracket 275 is formed so as to releasably fasten the second end of main connecting rod 220 to an operative portion of tooling module 400. As a result of this construction, as driven shaft 210 rotates, arbor 267 will rotate eccentrically about the longitudinal axis of driven shaft 210 so as to generate a reciprocating movement of main connecting rod 220. This arrangement is adapted to create stroke- forces of approximately 5 tons peak at coupling bracket 275.

In one preferred embodiment, an energy storage spring 278 is fastened between a portion of main connecting rod 220 and housing 100 (Fig. 1) so as to store energy on the reverse stroke of main connecting rod 220. Energy storage spring 278 reduces the amount of energy transferred from driven shaft 210 to main connecting rod 220 on each reverse stroke so as to reduce wear and tear on conventional clutch-brake mechanism 227. The energy stored in spring 278 is reapplied to main connecting rod 220 on each forward stroke.

Referring to Figs. 1 and 8 - 13, multicrank assembly 300 is operatively engaged by drive shaft 205 so as to provide reciprocating motive force to plurality of quills 310 and to feed components 10 into and through tooling module 400. More particularly, multicrank assembly 300 comprises a main body portion 302, a hitch feed assembly 304, a second crank assembly 306, and a third crank assembly 308. Main body portion 302 comprises a substantially cylindrical base that is rotatably mounted on second end portion 235 of drive shaft 205. Main body 302 is coaxially mounted on drive shaft 205, and operatively supports hitch feed assembly 304, second crank assembly 306, and third crank assembly 308.

Hitch feed assembly 304 comprises a first crank 315, a hitch arm 318, and a rocker arm 321. More particularly, first crank 315 comprises a disk that is eccentrically mounted to main body 302 (Fig. 9) so as to project outwardly from main body 302 and be disposed in offset -relation to the longitudinal axis of drive shaft 205. First crank 315 typically comprises a diameter that is relatively smaller than main body 302. A portion of hitch arm 318 includes an annular receptacle portion 323 sized so as to have first crank 315 mounted within it. Hitch arm 318 projects outwardly from annular receptacle portion 323 in transverse relation to first crank 315. A free end 324 of hitch arm 318 is positioned in spaced- relation to annular receptacle portion 323. Rocker arm 321 comprises a first end 326 and a second end 329. A central pivot hole 323 is disposed between first end 326 and second end 329, and is adapted to accept a pivot pin so as to pivotally mount rocker arm 321 to a portion of housing 100. First end 326 is pivotally fastened to free end 324 of hitch arm 318. Second end 329 is pivotally fastened to a conventional metal strip feed mechanism (not shown) of the type that is adapted to selectively move a strip of metal into the working area of, e.g., a stamping and forming die or assembly machine. Second crank assembly 306 comprises a second crank 333, a second connecting rod 335, a quill clamp 338, and a bearing guide plate 341. More particularly, second crank 333 comprises a disk that is eccentrically mounted to first crank 315 so as to project outwardly therefrom (Fig. 9) . Second connecting rod 335 includes an annular receptacle portion 343 sized so as to have second crank 333 mounted within it. Second connecting rod 335 projects outwardly from annular receptacle portion 343 in transverse relation to second crank 333. A free end 344 of second connecting rod 335 is positioned in spaced- relation to annular receptacle portion 343. Free end 344 is fastened to quill clamp 338, via bolt 348. A quill 310 is releasably fastened to quill clamp 338 so that a lower portion of the quill is disposed within a bore defined within quill clamp 338. It will be understood that quills 310 may comprise elongate, substantially rigid shafts having forming, cutting, or insertion tools disposed at an end located adjacent to tooling module 400. A dowel pin 353 projects outwardly from a portion of quill clamp 338 and includes a slider 356 disposed at its free end. Bearing guide plate 341 is mounted on housing 100 so as to be disposed in confronting relation with quill clamp 338. Bearing guide plate 341 defines at least one slot 359 that is adapted to slidingly receive slider 356 so as to guide the up and down reciprocating motion of quill clamp 338 and quill 310 during the operation of assembly machine 5.

Third crank assembly 308 comprises a third crank 368, a third connecting rod or quill driver 371, and sliders 373. More particularly, third crank 368 comprises a dowel -like disk that is eccentrically fastened to, and projects outwardly from, second crank 333 so as to be disposed in substantially parallel relation to second end portion 235 of drive shaft 205. Quill driver 371 comprises a shaft having a first end 374 and a second end 376. First end 374 is pivotally fastened to third crank 368 and second end 376 is fastened to a second quill clamp 375, and therethrough to a second quill 310. As with second crank assembly 306, third crank assembly 308 includes a dowel and slider assembly that is adapted to slide within a slot defined in bearing guide plate 341 so as to guide the reciprocating motion of second quill 310 during operation of assembly machine 5.

Referring now to Figs. 1, 8, and 14, tooling module 400 is adapted to be mounted on housing 100 directly below the tooling end of plurality of quills 310. Tooling module 400 is of a modular design inasmuch as numerous different tooling modules may be interchangeably secured to assembly machine 5, depending upon the particular manufacturing operation to be performed. A portion of tooling module 400 is disposed in confronting relation to coupling bracket 275 of main connecting rod 220 and is adapted to be releasably fastened thereto. Tooling module 400 is of a type that is capable of bending, blanking, and/or coining metal or polymer components prior to, or during, the transferring and/or insertion of those components into housings (not shown) . Preferably the housings that are to be stitched are disposed within a positioning tray having recesses formed therein to receive and hold the housings (not shown) . Assembly machine 5 may be used to perform fabrication operations on plurality of components 10, prior to insertion of the components into a corresponding housing, in the following manner. More particularly, the reciprocating motions of the main connecting rod 220 and multicrank assembly 300 are synchronized with one another according to a sinusoidal relationship. Consequently, the fabrication operations of both the quills 310 and tooling module 400 may be appropriately sequenced by reference to a sinusoidal curve representing the positional relationship of the moving parts of assembly machine 5 as a function of time. It will be understood that various known periodic and semi-periodic functions, e.g., sine, cosine, saw tooth, cycloidal, etc., may be used in connection with determining the positional relationship of the moving parts of assembly machine 5 without departing from the scope or spirit of the present invention.

Thus, as drive shaft 205 rotates main body 302, cranks 315, 333, and 368 are caused to orbit about the longitudinal axis of drive shaft 205. The eccentric positional relationship of each of cranks 315, 333, 368 on main body 302 provides for both the timing of the various operations and the magnitude of the forces generated by each of the crank assemblies according to the foregoing sinusoidal relationship. More particularly, as crank 315 orbits about the longitudinal axis of drive shaft 205, hitch arm 318 is caused to reciprocate in a plane transverse to drive shaft 205. As this occurs, rocker arm 321 is caused to reciprocally pivot about pivot hole 323 so as to drive a conventional metal strip feed mechanism. At the same time, second crank 333 and third crank 368 orbit about the longitudinal axis of drive shaft 205 and thereby reciprocatingly drive second connecting rod 335 and quill driver 371. The reciprocating movement of second connecting rod 335 and quill driver 371 causes plurality of quills 310 to move up and down in synchronous relation to (i) the advance of components 10 into tooling module 400, and (ii) the reciprocating movement of main connecting rod 220. In each case, the phase relationship between the various reciprocating parts may be determined according to the foregoing known periodic or semi-periodic functions.

Synchronized with the foregoing operations is the reciprocating movement of main connecting rod 220. More particularly, driven shaft 210 is captured within eccentrically positioned bore 271 of arbor 267 so that, as driven shaft 220 rotates, arbor 267 is caused to rotate eccentrically about driven shaft 210 and thereby to generate the reciprocating movement of main connecting rod 220. Coupling bracket 275 is fastened to a drive portion of tooling module 400 so as to operate a die punch or the like and thereby to either form, bend, or coin, the individual components 10 as they are synchronously moved through tooling module 400 by hitch feed assembly 304. Again the phase relationship between the position of main connecting rod 220 and either of hitch feed assembly 304, second crank assembly 306 or third crank assembly 308 may be determined by reference to the foregoing periodic or semi-periodic function. As a result of this construction, the forming, bending, or coining operations performed by tooling module 400 may be synchronized with the reciprocating motion of plurality of quills 310 so as to sequentially perform final manufacturing operations on components 10.

The operations may be performed prior to, or during insertion of components 10 into housings by an insertion portion of quills 310. It is to be understood that the present invention is by no means limited to the precise constructions herein disclosed and shown in the drawings, but also comprises any modifications or equivalents within the scope of the claims.

Claims

What Is Claimed Is:

1. An assembly machine adapted for performing fabrication operations on a plurality of components prior to insertion of the components into cavities defined within a corresponding housing, said assembly machine comprising: a housing comprising a plurality of walls; a drive assembly operatively supported by said housing; a first reciprocating mechanism supported by said housing and motivated by said drive assembly so as to provide reciprocating motion to a first tooling module in a first operating direction; and a second reciprocating mechanism supported by said housing and motivated by said drive assembly so as to provide reciprocating motion to a second tooling module in a second operating direction; wherein said reciprocating motions generated by said first and second reciprocating mechanisms are synchronized according to a sinusoidal relationship.

2. An assembly machine according to claim 1 wherein said first tooling module and said second tooling module cooperate to perform said fabrication operations upon said components.

3. An assembly machine according to claim 2 wherein said drive assembly includes a drive shaft and a driven shaft each being rotatably supported by said housing, said drive shaft being positioned in rotatable engagement with said driven shaft and including a first end that is rotatably engaged by a motor.

4. An assembly machine according to claim 3 wherein said first reciprocating mechanism includes a multicrank assembly supported by said housing and rotatably engaged by a second end of said drive shaft.

5. An assembly machine according to claim 4 wherein said multicrank assembly includes a first eccentrically mounted crank that drivingly engages a hitch feed so as to synchronously move said components into said first and second tooling modules.

6. An assembly machine according to claim 5 wherein said multicrank assembly includes an eccentrically mounted second crank and an eccentrically mounted third crank each having an arm that is actuatingly engaged with said first tooling module so as to synchronously and reciprocatingly drive said first tooling module.

7. An assembly machine according to claim 6 wherein said first tooling module comprises a plurality of quill tools adapted for manipulating at least a portion of said components .

8. An assembly machine according to claim 7 wherein at least one of said quill tools is adapted to perform a fabrication operation upon said components.

9. An assembly machine according to claim 7 wherein at least one of said quill tools is adapted to insert said components into said cavities of said housing.

10. An assembly machine according to claim 3 wherein said second reciprocating mechanism includes a main connecting rod comprising a receptacle end and a coupling end, said receptacle end having a portion of said driven shaft eccentrically mounted therein so that said main connecting rod is reciprocatingly driven in response to rotative movement of said driven shaft and said coupling end being disposed in driving engagement with said second tooling module whereby motive force is provided for reciprocally actuating said second tooling module.

11. An assembly machine according to claim 10 wherein said second tooling module comprises a modular die tool.

12. An assembly machine according to claim 10 wherein said main connecting rod includes an energy storage mechanism for storing a portion of the energy generated by said second reciprocating mechanism during an outward strike.

13. An assembly machine according to claim 12 wherein said energy storage mechanism comprises a spring that is fastened to a portion of said main connecting rod and to a portion of said housing.

14. An assembly machine adapted for performing fabrication operations on a plurality of components prior to insertion of the components into cavities defined within a corresponding housing, said assembly machine comprising: a housing comprising a plurality of walls; a drive assembly operatively supported by said housing; a first reciprocating mechanism supported by said housing and motivated by said drive assembly so as to provide synchronized reciprocating motion to a first tooling module in a substantially-vertically oriented direction relative to said housing; and a second reciprocating mechanism supported by said housing and motivated by said drive assembly so as to provide synchronized reciprocating motion to a second tooling module in a substantially-horizontally oriented direction relative to said housing; wherein said reciprocating motions generated by said first and second reciprocating mechanisms are synchronized relative to one another according to a sinusoidal relationship so that said fabrication operations are performed in synchronized relation with said insertion of said components into said cavities.

15. An assembly machine according to claim 14 wherein said drive assembly includes a drive shaft and a driven shaft each being rotatably supported by said housing, said drive shaft being positioned in rotatable engagement with said driven shaft and including a first end that is rotatably engaged by a motor.

16. An assembly machine according to claim 15 wherein said first reciprocating mechanism includes a multicrank assembly supported by said housing and rotatably engaged by a second end of said drive shaft.

17. An assembly machine according to claim 16 wherein said multicrank assembly includes a first eccentrically mounted crank that drivingly engages a hitch feed so as to synchronously move said components into said first and second tooling modules.

18. An assembly machine according to claim 17 wherein said multicrank assembly includes an eccentrically mounted second crank and an eccentrically mounted third crank each having an arm that is actuatingly engaged with said first tooling module so as to synchronously and reciprocatingly drive said first tooling module.

19. An assembly machine according to claim 18 wherein said first tooling module comprises a plurality of quill tools adapted for manipulating at least a portion of said components .

20. An assembly machine according to claim 19 wherein at least one of said quill tools is adapted to perform a fabrication operation upon said components.

21. An assembly machine according to claim 19 wherein at least one of said quill tools is adapted to insert said components into said cavities of said housing.

22. An assembly machine according to claim 15 wherein said second reciprocating mechanism includes a main connecting rod comprising a receptacle end and a coupling end, said receptacle end having a portion of said driven shaft eccentrically mounted therein so that said main connecting rod is reciprocatingly driven in response to rotative movement of said driven shaft and said coupling end being disposed in driving engagement with said second tooling module whereby motive force is provided for reciprocally actuating said second tooling module.

23. An assembly machine according to claim 14 wherein said second tooling module comprises a modular die tool.

24. An assembly machine adapted for performing fabrication operations on a plurality of components prior to insertion of the components into cavities defined within a housing, said assembly machine comprising: a housing comprising a plurality of walls; a drive assembly including a drive shaft and a driven shaft each being rotatably supported by said housing, said drive shaft being positioned in rotatable engagement with said driven shaft and including a first end that is rotatably engaged by a motor; a main connecting rod comprising a receptacle end and a coupling end, said receptacle end having a portion of said driven shaft eccentrically mounted therein so that said main connecting rod is reciprocatingly driven in response to rotative movement of said driven shaft and said coupling end being disposed in driving engagement with a tooling module whereby motive force is provided for reciprocally actuating said tooling module; and a multicrank assembly supported by said housing and rotatably engaged by a second end of said drive shaft, said multicrank assembly including a first eccentrically mounted crank that drivingly engages a hitch feed so as to synchronously move said plurality of components into said tooling module and second and third eccentrically mounted cranks each having a quill tool mounted on an arm so as to synchronously and reciprocatingly drive said quill tools into engagement with a portion of said components and thereby to manipulate at least a portion of said components.