WO1999026742A2

WO1999026742A2 - Machine for attaching fasteners

Info

Publication number: WO1999026742A2
Application number: PCT/US1998/025186
Authority: WO
Inventors: Howard Franklin Greenwalt; Michael Alan Lyle
Original assignee: Scovill Fasteners Inc.
Priority date: 1997-11-26
Filing date: 1998-11-25
Publication date: 1999-06-03
Also published as: WO1999026742A3; WO1999026742A9; AU1703299A

Abstract

An improved machine (10) for attaching fasteners to textiles or other foundation or substrate material is disclosed. The disclosed machine has changeable, modular tool assemblies (20, 22) and hopper assemblies (24, 26) that provide error-free attachment of fasteners, and rapid change of fastener tools and parts, during operation. The machine also has a drive assembly (32) with a minimum of working parts, mounted onto a single panel (38) so as to provide easy access for maintenance, troubleshooting and repair. The machine has a microprocessor-driven control system (18) and a multi-frequency inverter that automate the operation at variable settings and speeds. Other unique features include a means of detecting 'brown-out' conditions, a tamper-resistant safety mechanism (34), a laser guide (228) for aligning work-pieces, and a telescoping pedestal (28) and ergonomic footrest (226) for height and comfort adjustment.

Description

MACHINE FOR ATTACHING FASTENERS DESCRIPTION Technical Field

This invention relates to machines for attaching fasteners to textiles or other foundation or substrate material, as for example, snap fasteners to clothing. These machines are known in the art as attaching or setting machines. Specifically, this invention relates to attaching machines that have changeable, modular tool assemblies and changeable, modular accessories such as hoppers for storing and feeding fastener parts. This invention also relates to attaching machines that incorporate elements of automated technology. Background Art

Snap fasteners, for example, studs or sockets, are attached to apparel fabric by pressing two complementary fastener parts together, with the fabric in between them, so that the parts crimp together through the fabric in firm attachment. A setting or attaching machine having a descending plunger to engage or carry the upper fastener part and a rising plunger to engage and carry the lower fastener part accomplishes this pressing action. During the process, the fabric remains stationary. Attaching machines of this sort have been around since at least the beginning of this century. An example is shown in U.S. Patent No. 937,150 to Arthur R. Havener, which issued October 19, 1909. These machines typically have hoppers for automatically feeding the fastener parts down separate tracks to upper and lower guides associated with the upper and lower plungers, respectively.

In the past, when one wanted to change the machine's operation from the installation of one pair of complementary fastener parts to the installation of another pair— for example, from a socket and prong ring to a stud and post, or to a tack and burr— or from the installation of one size of fastener parts to the installation of another size, one would have to change the tools in the plungers so that they would mate perfectly with associated fastener parts. One would also have to change the contents of the hoppers and change the tracks associated with the upper and lower guides. With machines seen in the prior art, the task of changing tools and hoppers requires numerous tools and the skills of an experienced operator or machinist. The attaching machine parts have to be manipulated into position. Care has to be taken to see that the tools and hopper tracks are properly aligned so that the subsequent setting of fastener parts comes off with no misalignments, mangling of parts, or bad connections. Done properly, the whole process can take up to half an hour to complete. In an industry which relies on these machines and their operators to handle large volumes of work product on a daily basis, this time-consuming and error-prone process of changing tools and hoppers obviously interrupts work flow and increases the chances of shoddy workmanship.

It is one object of the present invention to provide a machine design by which the changing of tools and hoppers to accompany the changing of fastener parts may be performed in virtually no time at all and without error. In addition, under the new arrangement, the changing may be done readily by the attaching machine operator himself or by other relatively unskilled personnel, and with a tool as simple as an Allen wrench.

It is another object of this invention to provide a design that facilitates routine cleaning, diagnostic and repair work. By virtue of their continuous use over a period of time, attaching machines will become clogged with lint, dirt and other debris. Clogging can accelerate the wear of machine parts, decrease the quality of performance, and cause machines to break down. To ensure their smooth operation, attaching machines require regular maintenance. Like the changing of tools and hoppers, maintenance work can be time-consuming and difficult. The present invention offers a new design for an attaching machine in which the working parts are kept to a minimum and are easily accessible to the machinist or operator. As already stated, attaching machines accomplish the task of attaching fasteners to fabric or some other foundation or substrate by pressing the complementary fastener parts together with great force and speed. The action of the descending and rising plungers coming together creates a substantial risk of bodily injury to the operator. Specifically, fingers, hair or loose, dangling .articles may get caught between the tools. Given this risk, attaching machines generally have some safety mechanism built into them.

Safety mechanisms in the prior art have their problems, however. Some are prone to malfunction or failure. Others can be purposely disabled during operation, for the sake of increasing the working speed of the operator. It is another object of the present invention to provide a safety mechanism that operates effectively and unfailingly. This mechanism cannot be purposely disabled during operation.

The present invention also incorporates elements of automated technology into the operation of an attaching machine. Specifically, a microprocessor controls and automates the operation of this machine. The control system also monitors the AC current for "brown-out" conditions and will shut the machine down when it detects such conditions. The pedestal on which the machine stands can be adjusted automatically with a foot pedal. The drive motor is driven by a multi- frequency inverter that enables one to control the acceleration, speed and frequency of the motor. A diode laser target light assists with the alignment of work-pieces.

By fulfilling the objectives described above, the present invention markedly improves upon the attaching machine invention disclosed and claimed in U.S. Patent No. 5,463,807 to Anton Hochhausl, issued November 7, 1995. Although the Hochhausl machine also disclosed and claimed changeable tool assemblies, the design and construction of its assemblies could not eliminate misalignments, or "skew," between the upper and lower plungers and tools. The present invention successfully eliminates any skew in the operation of the tool assemblies. In general, this invention successfully applies the basic principles of simplicity in design and modularity in components to an attaching machine that is more versatile, durable, powerful and accurate than any presently seen and used in the industry.

Disclosure of Invention

The present invention is a high-performance machine for attaching fasteners. It has a lightweight, aluminum housing and a double cam drive assembly with a minimum of working parts. One side of the housing can be easily and quickly removed so that cleaning, diagnostic and repair work can be performed on the machine parts, which remain attached to the other side of the housing.

The tools and hoppers are modular in their design and construction; to change them, all the operator has to do is to remove the entire assembly and to install a different assembly. Guide pins and strict dimensional tolerances in the housing ensure that the tool assemblies are perfectly and rigidly aligned when installed. A new design for a rotary hopper is also provided.

This invention also features (1) an electric, non-air driven, safety mechanism, (2) a laser target light to assist in the alignment of work- pieces, and (3) an electrically driven, telescoping pedestal to adjust the height of the machine. The pedestal is equipped with an ergonomic footrest. The control box for the drive motor features a microprocessor and a means for linking the operation of a plurality of attaching machines in synchrony. An aluminum panel on which the control box is mounted serves as the heat sink. The machine controls are consolidated so that the operation of the machine is greatly simplified.

These and other novel features of the present invention will become apparent to the reader from the drawing figures listed below and provided herewith, and from the detailed description of the preferred embodiments provided below. Brief Description of Drawings

FIG. 1 is a side schematic view of the operative body of the attaching machine of the present invention. FIG. 2 is another side schematic view of the operative body, with the tool assemblies and the hopper assemblies removed, so that one has clear picture of the elements of the drive assembly.

FIG. 3 is close-up, side schematic view of a portion of the operative body depicted in FIG. 1. FIG. 4 is a front schematic view of the operative body, intended to show the attachment and placement of the hopper assemblies and tracks relative to the tool assemblies in the housing.

FIG. 5 are side and front schematic views of the upper tool assembly of the present invention, with the laser target light and the plunger in retracted position.

FIG. 6 is a bottom schematic view of a portion of the guide for the upper tool assembly with a pivoting bridge.

FIG. 7 is a top schematic view of the lower tool assembly of the present invention, showing the guide, a pivoting crook, and the die. FIG. 8 is a side schematic view of the hopper of the present invention, showing the internal layout of the hopper cone.

FIG. 9 are side schematic and front schematic views of the hopper, the side schematic view showing the placement of the external hopper bridge relative to the external face of the hopper cone, and the front schematic view showing part of the hopper spindle. FIG. 10 is a wiring diagram showing the elements of the control box of the present invention and how they are wired together.

FIGS. 11 and 12 are layouts of the hinged control panel onto which the control box is mounted, and the hinged switch plate onto which the switch box is mounted, respectively.

FIG. 13 is another side schematic view of the operative body.

FIG. 14 is a close-up side schematic view of the drive motor and the gear box, showing how they are mounted to the operative body.

FIG. 15 is a side schematic view of the safety assembly. FIG. 16 is a transparent view of the upper plunger assembly.

FIG. 17 are schematic views showing the upper pusher in articulation relative to the upper guide and pivoting upper bridge.

FIG. 18 is a top view of the lower guide and pivoting lower crook. FIG. 19 is a side schematic view of the lower tool assembly and the lower pusher.

FIG. 20 is a side schematic view of the upper tool assembly and the upper pusher.

FIG. 21 is another side schematic view of the operative body, this time showing the timing belt for the hopper motor and the return springs for the pusher assembly and the pusher handle assembly.

FIG. 22 is a top plan view of the face of the switch plate. Best Mode for Carrying Out the Invention

In the preferred embodiment, the attaching machine 10 of this invention comprises an operative body 12, a drive motor 14, a gear box

16, an external control system 18, upper and lower tool assemblies 20 and 22, right and left hopper assemblies 24 and 26, and a pedestal 28. FIGS. 1-3 illustrate the operative body 12 of an attaching machine 10. (See also FIGS. 13 and 21.) The operative body 12 comprises a housing assembly 30, a drive assembly 32, and a safety assembly 34. The housing assembly 30 is made up of two vertically oriented, side plates, right 36 and left 38, a bottom plate 40, and several spacer elements that join the two side plates together and define the internal space between the side plates for housing the drive assembly 32 and the upper and lower tool assemblies 20 and 22. (In this description, the right and left sides or halves of the machine are from the perspective of an observer, looking at the machine from the front to the back.) Specifically, there is a rear spacer 42, a front spacer 44 positioned above the upper tool assembly 16, a spacer 46 positioned in front of the drive motor 14, two top spacers 48, and a bottom spacer 50. The bottom spacer 50 is mounted onto the bottom plate 40, which in turn is mounted onto the pedestal 28. To minimize weight, all of the plates and spacers of the housing assembly are preferably constructed from anodized aluminum.

Additionally, the housing assembly has two drive motor mounts 52 and 54 for mounting the drive motor 14 and the associated gear box 16 to the housing assembly 30, and a hopper drive motor mount 56 for mounting a hopper drive motor 58 to the housing assembly 30. The drive motor mounts 52 and 54 are secured to the left side plate 38 on its exterior face. (See FIG. 14.) The use of spacer elements minimizes the weight of the housing assembly, and yet produces a strong, rigid, three- dimensional structure that can be machined and assembled to tight tolerances. What is unique about the design and fabrication of the housing assembly 30 is that the entire drive assembly 32 is mounted for complete articulation and operation onto the left side plate 38. The right side plate 36 is an easily removable cover; its removal exposes the drive assembly 32 to easy access for cleaning, troubleshooting and repair. The drive motor 14 can be disabled and the drive assembly 32 can be driven manually by turning a drive shaft 60 at its free end with a manual implement. In this manner, the relative movement of all of the elements of the drive assembly 32 can be observed by a machinist or operator, and any problems such as blockage, or worn or broken parts, can be identified quickly and addressed with ease. As seen in FIGS. 1 and 2, the drive motor 14 is positioned vertically, with the operative end of the drive shaft 60 pointing downward.

The drive assembly 32 uses a double cam arrangement to move both an upper drive assembly 80 and an lower drive assembly 82. (See FIGS. 1 and 2.) The upper drive assembly 80 basically consists of a yoke

84 that is pivotably mounted to the side plates 36 and 38 by means of an upper shaft 86 and an upper shaft support 88, and an upper pitman 90 that is articulably connected to the yoke 84 by an upper drive pin 92. A yoke/ pitman spacer 94 separates the inter-articulating ends of the yoke 84 and the upper pitman 90. The upper pitman 90 fits over an upper cam 96 which is integral with a cam shaft 98. Fastened to the free end of the yoke 84 are two plunger tabs 100 which engage an upper plunger 102 in the upper tool assembly 20.

Similarly, the lower drive assembly 82 basically consists of a lower elevating arm 104 that is pivotably mounted to the side plates 36 and 38 by means of a lower shaft 106 and a lower shaft support 108, and a lower pitman 110 that is articulably connected to the lower elevating arm 104 by a lower drive pin 112. The lower pitman 110 fits around a lower cam 114 and is held in place to the left side plate 38 by a lower pitman retainer 116. Fastened to the free end of the lower elevating arm

104 are two plunger tabs 100 which engage a lower plunger 118 in the lower tool assembly 22.

Also pivotably connected to the yoke 84 and the upper pitman 90 at the upper drive pin 92 is one end of a pusher/ yoke linkage 120. The other end of the pusher/ yoke linkage 120 is articulably connected to a pusher lever 122 with a yoke linkage screw 123. The pusher lever 122 is pivotably secured to the left side plate 38, at a point approximately one- fifths of its length from the end that articulates with the pusher/ yoke linkage, by means of a pusher lever shaft 124. The other end of the pusher lever 122 is articulably connected to a pusher linkage 126 which in turn engages an upper pusher 128 and a lower pusher 130. (See FIG. 3.) The pusher linkage 126 is fastened to the upper and lower pushers 128 and 130 with a union bolt 60. An access plate 62 covers the union bolt 60. The upper and lower pushers push the fastener parts down guides in the upper and lower tool assemblies 20 and 22 until the parts are engaged by the upper and lower plunger assemblies 140 and 162, respectively.

The pusher assembly is kept in a biased return position by a spring 64 that hooks at one end to the yoke linkage screw 123, as shown in FIG. 21. The pusher assembly is provided with a manual pusher handle 66 consisting of a pusher handle pivot 68, a pusher handle lever 70, and a pusher handle grip 72. The pusher handle 66 is pivotably mounted onto the exterior face of the left side plate 38; a large pin 74 welded in the pivot 68 engages the pusher lever 122, such that when the pusher handle 66 is pulled forward, the upper and lower pushers 128 and 130 are retracted. At this position, fastener parts can be loaded manually onto the tool guides and then manually pushed forward using the pusher handle. A spring 76 hooked at one end to the pin 74 and at the other end to a pin 78 mounted on the left side plate 38 keeps the pusher handle 66 biased toward a disengaged position, with the handle pointing toward the back.

The drive assembly 32 is driven by upper and lower cams 96 and 114 that are integral with a single cam shaft 98. The cam shaft 98 cooperates with a drive shaft in the gear box 16. The upper and lower shafts 86 and 106, which are preferably made from bronze, serve as the fulcrums for the efficient and powerful compressing action of the yoke 84 and the lower elevating arm 104.

The housing assembly 30 is fitted with eight tool frame guide pins 132 which function as "rails" for sliding the upper and lower tool assemblies 20 and 22 in and out of the housing. The guide pins are mounted to the side plates so as to form upper and lower pairs of opposing rows, two guide pins to a row, for the upper and lower tool assemblies. They act as guides for the precise placement of the tool assemblies within the housing. (See FIGS. 1 and 3.) The tool assemblies are modular in design; all of the working parts — the tool frames, the guides, the plungers— are fitted together into a single unit. Changing or replacing a tool is therefore as easy as unscrewing the screws that lock a tool assembly into position and pulling that tool assembly out of the housing, and pushing another tool assembly into position inside the housing and screwing the locking screws back into the housing. As seen in FIGS. 19 and 20, the tool frames have sliding elements 232 that resemble the tines of a fork; these sliding elements engage the guide pins 132.

The upper tool assembly 20, (see FIGS. 5, 6, 16, 17 and 20), basically consists of an upper tool frame 134, an upper guide plate 136, an upper guide 138, and an upper plunger assembly 140. The upper guide 138 consists of four segments mounted onto the upper guide plate 136; the front right segment swings outward by means of a spring- loaded release pin to permit operator access for cleaning and maintenance. The upper plunger assembly 140 consists of an upper plunger housing 142 that is formed to engage the plunger tabs 100 of the yoke 84, an upper plunger sleeve 144 which slides inside the plunger housing, and an upper plunger die holder 146 which is fitted with a spring 147 and inserted into the plunger sleeve and held with a wrist pin 148. A tool die 150 is then inserted into the plunger die holder. In operation, a fastener part slides off the track and onto a pivoting bridge 152. The upper pusher 128 then pushes the fastener part forward and off the bridge, pushes the bridge aside, and moves the fastener part down the upper guide to be engaged by the tool die and an upper fastener part receiver 153. By means of the spring-loading, the upper plunger assembly will automatically compensate for varying fabric thickness.

Similarly, the lower tool assembly 22, (see FIGS. 7, 18 and 19), consists essentially of a lower tool frame 154, a lower guide plate 156, a lower guide 158, lower jaws 160 and a lower plunger assembly 162. The lower guide 158 consists of four segments mounted onto the lower guide plate 156; the front right segment swings outward by means of a spring-loaded release pin to permit operator access for cleaning and maintenance. The lower plunger assembly 162 is notched to engage the plunger tabs 100 of the lower elevating arm 104. It has a cylindrical space to engage a tool die 150. The lower tool frame 154 has a relief for clearing debris from the lower jaws 160, which are also spring-loaded for easy clean-out. In operation, a fastener part slides off the track and onto a pivoting crook 164. The lower pusher 130 then pushes the fastener part forward and off the crook, pushes the crook aside, and moves the fastener part down the lower guide to be engaged by the tool die. The frame construction for the upper and lower tool assemblies 20 and 22 enhances their performance by enabling the tools to be driven together with greater mechanical forces than machines in the prior art but without sacrificing needed accuracy and precision.

The attaching machine of the present invention features an electric-powered safety assembly 34, as seen most clearly in FIG. 15. The safety assembly 34 is mounted onto the exterior face of the left side plate 38. The operative mechanism in the assembly 34 consists of a safety drive lever 166, which is articulably connected to a safety drive plate 168, a nylon safety slide 170 which is connected to the other end of the safety drive plate 168, and an aluminum safety guard 172 which is fastened to the safety slide 170. (See also FIG. 2.) Both the nylon safety slide 170 and the aluminum safety guard 172 are disposed within the housing, between the right and left side plates. The safety drive lever

166 pivots on a safety drive pin 174 that is mounted to the left side plate 38. The short arm of the safety drive lever 166 is connected to a solenoid 175 which is secured to the left side plate 38 with a solenoid mount plate 176. Positioned below the safety drive lever 166 is a safety switch plate 177. When the safety drive lever 166 pivots in response to an electric current flowing through the solenoid 175 that moves its short arm, its long arm activates a micro switch on the safety switch plate 177. As a result, the safety guard 172 automatically descends when the upper plunger 102 descends to meet the ascending lower plunger 118. With the safety guard in place, fingers, loose hair or other dangling objects cannot get caught between the two plungers.

The operation of the attaching machine is controlled by a microprocessor. A wiring diagram showing the different electronic components and their circuitry appears as FIG. 10. The use of electronic controls enables one to link up a series of attaching machines and to operate them in synchrony with each other. The components are mounted onto a control panel 178 cut from a sheet of aluminum. (See FIG. 11.) The panel thus acts as a heat sink. It is mounted to the housing with hinges so that it can swing outward to permit removal of the right side plate 36. The controls for the attaching machine have been consolidated so that the machine starts and stops using two switches — a run/ stop/ manual switch and a start switch— located on the switch plate 180. (See FIG. 22.)

A computer-controlled, multi-frequency inverter operates the drive motor 14. It provides controllable acceleration, deceleration, braking, speed, drive frequency and torque. The drive motor operates only for the machine cycle duration; this feature conserves energy, reduces machine heating, and increases the life of the drive motor. The control system 18 has automatic safety features that include a programmable torque overload shutdown mechanism. The control system 18 watches the AC power for "brown-out" conditions and will shut the system down if such conditions are detected. This feature is especially useful in operations overseas, where the electric power supply is not as reliable and uninterruptible as that available in this country. A proximity sensor is mounted onto a drive sensor bracket at a position close to the gear box 16. Mounted on the external face of the gear box 16 is a metal "flag" that the sensor sees. (See FIG. 14.) The flag provides a signal used for machine cycle timing.

This invention provides an improved design for a rotary hopper. (See FIGS. 4, 8 and 9.) Both the right and left hopper assemblies 24 and

26 include the following components: a hopper base 182, a hopper base patch 184, a hopper base insert 186, top and bottom hopper base plates 188 and 190, a hopper bearing block 192, a hopper drive pin 194, a hopper cone 196 and a sweep 198. These parts are assembled in a typical sandwich-like construction. Each hopper has a clear plastic reservoir 200 with a release block 202 and a release pin 204 for emptying of the fastener parts. Each reservoir 200 has a slot cover 206 on the side and a main cover 208 at the top. Two hopper clamps 210 secure each hopper assembly to the housing. A hopper spindle 212 rotates the hopper cone 196 to agitate the stored fastener parts. The hopper cone

196 has a concave curvature from the inside, much like a pie plate; the entire assembly is reinforced on the outside by the use of an external hopper bridge 214. The use of this bridge gives the hopper assembly the needed structural integrity while minimizing the material needed to construct the hopper parts. As the hopper cone 196 rotates, the fastener parts are released onto narrow nickel plated tracks 216 and down to the upper and lower guides 138 and 158. The hopper assemblies are mounted onto the housing, the left hopper assembly 26 with the reservoir facing the housing and the right hopper assembly 24 with the reservoir opposite the housing. A single hopper spindle 212 driven by a hopper drive motor 58 rotates both hopper cones 196. The hopper drive motor 58, mounted in a horizontal position with the drive shaft perpendicular to the plane of the side plates, is connected to a pulley shaft 218 set within a pulley shaft block 220. A timing belt 222 transfers the torque from the pulley shaft 218 to the hopper spindle 212. (See FIG. 21.)

The pedestal 28 preferably adjusts the height of the machine to suit the operator. It has a telescoping body that increases in height in response to an electrically driven means. The adjustment mechanism can be operated with a foot pedal 224 which can be mounted onto an ergonomic footrest 226 for either right foot or left foot operation. The ergonomic footrest 226 is a U-shaped aluminum platform that fits around, and bolts permanently to, the telescoping pedestal 28 near its base. The position of the footrest 226 can be adjusted in two dimensions — the elevation and the angular tilt. The elevation of the footrest rises or falls with the adjustment of the pedestal height. The angular tilt of the footrest can be adjusted manually with a hand screw. The footrest is ergonomic in nature because the operator can adjust the elevation of the footrest during breaks in a workday, when he or she is supposed to adjust both the height of the chair and the height of the machine to keep the joints and muscles from remaining in one position for an extended period of time.

The machine is equipped with a low power diode laser 228 that is directed to a reflecting mirror 230 mounted to the upper pusher 128. (See FIG. 5.) The light beam reflects off the mirror 230 in a direction perpendicular to the surface of the fabric or other substrate. The laser 228 has four adjustable brightness settings including an off setting. For safety, the laser 228 turns off automatically during each cycle of the machine. The laser allows an operator to align the work-piece with the tool dies.

While preferred embodiments and modes of use of the invention have been shown and described above, it will be apparent to those skilled in this art that various modifications may be made that would not depart from the spirit of the present invention. For that reason, the scope of the invention is set forth in the claims below.

Industrial Applicability

As already stated, this invention is used to attach fasteners to textiles or other foundation or substrate material. The foregoing description already describes in detail the invention's application and exploitation in industry. Recapitulated below, however, are the attaching machine's principal features and modes of use.

The machine is particularly useful in the high-volume manufacture of clothing and other textile goods where operator speed and efficiency are critical to productivity and reduction of waste. The machine's changeable, modular tool assemblies and hopper assemblies enable an operator, with minimal effort, to switch from one set of fastener tools and parts to another set relatively quickly and without error. The simplicity and accessibility of the machine's drive mechanism permits an operator to clean thoroughly any working parts, freeing them of lint, dirt and other debris, to ensure that the machine operates smoothly during long periods of continuous use. The machine's microprocessor-based control system and multi-frequency inverter drive system automate and fine-tune the operation. In summary, this invention speeds up the fastener attachment process and minimizes interruptions in the work flow. It also minimizes errors in the attachment process, thereby reducing waste in the way of rejected work-pieces and damaged or misaligned fastener parts.

At the same time, this invention has features specially designed for operator comfort and safety. The machine's control system monitors for "brown-out" conditions typical in localities where the power supply may not be completely reliable. The machine has an improved safety mechanism that cannot be purposely disabled, thereby ensuring that operator safety is not sacrificed for the sake of operating speed. The machine also has an electrically-driven adjustable pedestal and an ergonomic footrest for maximum operator comfort. In summary, the machine will find particular use in manufacturing operations employing a large number of unskilled laborers, where productivity and efficiency may sometimes take precedence over operator comfort and safety.

Claims

CLAIMSWe claim:

1. A machine for attaching fasteners to foundation or substrate material comprising an operative body comprising a drive assembly for carrying out the attachment process and a housing assembly to house the drive assembly, a drive means for driving the drive assembly, a control means for controlling the drive means, upper and lower fastener tool means compatible with the fastener or fasteners to be attached, a feeding means for feeding fastener parts for engagement by the upper and lower tool means, and a support means of supporting the machine in a stable, upright position, wherein the drive assembly consists of an upper drive assembly having a yoke that pivots about a first fulcrum point and a lower drive assembly having an elevating arm that pivots about a second fulcrum point, the yoke and the elevating arm each are operatively connected at one end to separate cams of a single cam shaft by respective upper and lower pitmans so that the yoke and the elevating arm provide a repeating, cyclic compressing action when the cam shaft is turned, and the yoke and the elevating arm each are operatively engaged at the other end with the upper and lower fastener tool means, respectively, so that compressive force created by the action of the yoke and the elevating arm is transferred to the upper and lower tool means to effect the attachment of a fastener.

2. The machine of claim 1, wherein the housing assembly consists essentially of two vertically oriented, side plates, a bottom plate for mounting the operative body to the support means, and a plurality of spacer elements that join the two side plates together and define an internal space between the side plates for housing the drive assembly; and the drive assembly is mounted for complete articulation and operation onto one of the side plates, the other side plate serving as a removable cover.

3. The machine of claim 2, wherein the side plates, the bottom plate, and the spacer elements are manufactured from anodized aluminum.

4. The machine of claim 2, wherein the upper and lower tool means are changeable, modular upper and lower tool assemblies; the upper tool assembly consisting essentially of an upper plunger assembly having an upper plunger that engages the yoke and a tool die that engages a fastener part, the plunger driving the tool die downward to the foundation or substrate material; a guide means of guiding the fastener part to the tool die after the part exits the feeding means; and a tool frame for holding the guide means and the plunger assembly together as a single, integrated unit; the lower tool assembly consisting essentially of a lower plunger assembly having a lower plunger that engages the elevating arm and a tool die that engages a fastener part, the plunger driving the tool die upward to the foundation or substrate material; a guide means of guiding the fastener part to the tool die after the part exits the feeding means; and a tool frame for holding the guide means and the plunger assembly together as a single, integrated unit; wherein the means of feeding fastener parts for engagement by the upper and lower tool means includes a pusher assembly for pushing fastener parts into engagement with the tool dies of the upper and lower plunger assemblies in coordination with the compressing action of the yoke and the elevating arm; the pusher assembly consisting of a pusher lever pivotably mounted in a fixed position on the side plate onto which the drive assembly is mounted, articulably connected at one end to the yoke and the upper pitman by means of a pusher/ yoke linkage, and articulably connected at the other end to a pusher linkage that engages an upper pusher and a lower pusher, each of which pushes a fastener part down the guide means of the upper and lower tool assemblies, respectively, into engagement with the tool dies; and wherein the housing assembly includes a means of housing the upper and lower tool assemblies in secure but removable placement.

5. The machine of claim 4, wherein the means of housing the upper and lower tool assemblies in secure but removable placement consists of a plurality of guide pins mounted onto the side plates to form two pairs of opposing rows, sliding elements in the shape of fork tines formed in the tool frames of the upper and lower tool assemblies for sliding the tool assemblies into the housing assembly along the opposing rows of guide pins, and locking means for securing the assemblies into the position after they have been inserted into the housing assembly using the guide pins.

6. The machine of claim 4, wherein the pusher assembly includes a means for manually operating the upper and lower pushers.

7. The machine of claim 1, wherein the machine includes a safety mechanism for preventing injury to an operator of the machine.

8. The machine of claim 7, wherein the safety mechanism consists of a safety guard to prevent body parts and objects from becoming caught between the upper and lower tool means during the course of compression, and a means of automatically driving the safety guard downward into an effective position when the yoke and the elevating arm compress the upper and lower fastener tool means together.

9. The machine of claim 1, wherein the drive means consists of a drive motor and a gear box for turning the cam shaft.

10. The machine of claim 9, wherein the control means includes a microprocessor.

11. The machine of claim 10, wherein the control means includes a multi-frequency inverter.

12. The machine of claim 10, wherein the control means is mounted onto a control panel made from a sheet of aluminum and secured to the housing assembly by a means that permits the panel to swing outward.

13. The machine of claim 10, wherein the control means has two switches for an operator, one to start the machine and one to run or stop the machine or switch it to manual operation.

14. The machine of claim 10, wherein the control means includes a means of monitoring the power supply for "brown-out" conditions and shutting the machine down if such conditions are detected.

15. The machine of claim 1, wherein the feeding means includes two rotary hoppers with reservoirs for storing a supply of complementary fastener parts, the hoppers being removably mounted to the housing assembly; two tracks for delivering the fastener parts from the hoppers to the upper and lower fastener tool means; and a drive means for rotating the hoppers to load the fastener parts onto the tracks.

16. The machine of claim 15, wherein the rotary hoppers have an open, concave structure reinforced by an external bridge, and the reservoirs are equipped with release blocks for emptying the fastener parts.

17. The machine of claim 4, wherein the feeding means includes two rotary hoppers with reservoirs for storing a supply of complementary fastener parts, the hoppers being removably mounted to the housing assembly; two tracks for delivering the fastener parts from the hoppers to the guide means of the upper and lower tool assemblies; and a drive means for rotating the hoppers to load the fastener parts onto the tracks.

18. The machine of claim 1, wherein the support means is a electrically driven, telescoping pedestal.

19. The machine of claim 18, wherein an ergonomic footrest is mounted on to the pedestal near its base for right foot or left foot operation, the footrest having a means for adjusting the elevation and the angular tilt.

20. The machine of claim 1, wherein the upper and lower fastening tool means include a laser for aligning a work-piece with the tool means during the attachment process.