WO2022261751A1 - Appareil et procédé de changement d'outil de moulage - Google Patents

Appareil et procédé de changement d'outil de moulage Download PDF

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Publication number
WO2022261751A1
WO2022261751A1 PCT/CA2022/050915 CA2022050915W WO2022261751A1 WO 2022261751 A1 WO2022261751 A1 WO 2022261751A1 CA 2022050915 W CA2022050915 W CA 2022050915W WO 2022261751 A1 WO2022261751 A1 WO 2022261751A1
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WO
WIPO (PCT)
Prior art keywords
robot
mold
end effector
stations
plastic molding
Prior art date
Application number
PCT/CA2022/050915
Other languages
English (en)
Inventor
Joaquim Martins Nogueira
Adam Christopher ULEMEK
Sven Kmoch
Gerry Ha
Mikhail RABINOVICH
Timothy Tin Heng YEUNG
Marc Patrick VAN HEZEWYK
Original Assignee
Husky Injection Molding Systems Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Husky Injection Molding Systems Ltd. filed Critical Husky Injection Molding Systems Ltd.
Publication of WO2022261751A1 publication Critical patent/WO2022261751A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/48—Moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/48—Moulds
    • B29C2049/4856—Mounting, exchanging or centering moulds or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison

Definitions

  • PCT/CA2019/051205 filed August 29, 2019, PCT application no. PCT/CA2019/051204, filed August 29, 2019, PCT application no. PCT/CA2019/051202, filed August 29, 2019, PCT application no. PCT/CA2019/051203, filed August 29, 2019, and PCT application no. PCT/CA2021/050671, filed May 17, 2021, PCT application no. PCT/CA2019/051202 filed August 29, 2019, PCT application no. PCT/CA2022/050195 filed on February 10, 2022 are incorporated herein by reference.
  • This application claims priority from United States provisional patent application number 63/211,725, filed on June 17, 2021, the entire contents of which are incorporated herein by reference.
  • This relates to plastic molding, and more particularly, to tooling installation and changes in plastic molding systems.
  • Blanks often referred to as preforms
  • Blanks may be produced by injection molding, using molds customized for each possible blank size and configuration. Blanks may then be reshaped by blow molding, using molds customized for each possible size and configuration of final molded article.
  • An example plastic molding system comprises: a mold assembly, the mold assembly having external handling connectors; a press configured to receive the mold assembly and operable to produce plastic articles with the mold assembly; a robot movably mounted to a frame above the press, the robot having an end effector configured to matingly engage the handling connectors to lift the mold assembly, and the robot movable relative to the press to install the mold assembly to the press and to remove the mold assembly from the press.
  • the plastic molding system comprises a plurality of presses, each operable to receive a mold assembly, wherein the robot is movable to install a mold assembly to any of the plurality of presses and to remove a mold assembly to any of the plurality of presses.
  • the robot is movable on the frame along two horizontal axes.
  • the robot is movable along a vertical axis.
  • the robot comprises a wrist joint operable to rotate the end effector about a vertical axis.
  • the wrist joint permits only rotation of the end effector about the vertical axis, and wherein the wrist joint is the only rotational joint of the robot.
  • the plastic molding system comprises a controller for directing operation of the robot, wherein the controller is operable to release a connection between the press and the mold in response to engagement of the handling connectors by the end effector.
  • the frame is an enclosure.
  • the plastic molding system comprises a plurality of mold assemblies in a staging area within the enclosure.
  • the plurality of mold assemblies are positioned on a carrier and the carrier is registered to a datum in the staging area.
  • the enclosure comprises a window for receiving the carrier.
  • the plastic molding system comprises a conveyor system from the window to the staging area.
  • Plastic molding systems in accordance with this disclosure may comprise the above features in any operable combination.
  • An example plastic molding method comprises: molding plastic articles in a mold assembly installed at a press, by reciprocating the mold assembly between open and closed positions; moving a robot to the mold and engaging the mold assembly with the robot; and removing the mold assembly from the press with the robot.
  • the plastic molding method comprises moving the robot to any one of a plurality of presses, engaging the robot with a mold assembly installed at the any one of a plurality of presses, and removing the mold assembly from the any one of a plurality of presses. In some embodiments, the plastic molding method comprises rotating the robot about a vertical axis.
  • the rotating is at a wrist joint that permits only rotation about the vertical axis.
  • engaging the robot with the mold assembly comprises releasing a connection between the press and the mold assembly in response to engagement of the mold assembly by the robot.
  • the robot moves within an enclosure.
  • moving the mold assembly to a holding area within the enclosure using the robot the staging area containing a plurality of mold assemblies.
  • picking up a mold assembly from the holding area using the robot, and carrying the mold assembly to the press is a process of picking up a mold assembly from the holding area using the robot, and carrying the mold assembly to the press.
  • receiving a mold assembly through a window of the enclosure and transporting the mold assembly from the window to the staging area.
  • Plastic molding methods in accordance with this disclosure may include the above features in any operable combination.
  • An example robotic end effector for manipulating mold plates of a mold for producing plastic articles comprises: a first retainer for mating to a connector on a first mold plate; a second retainer for mating to a connector on a second mold plate; the first and second retainers rigidly mounted and spaced to hold the mold plates together while the retainers are mated to the connectors.
  • each connector comprises a cleat
  • the retainers comprise cleats configured to interlock with the connectors.
  • retainer comprises a slot configured to receive the corresponding connector.
  • the retainers are configured to engage the connectors by horizontal motion toward the mold plates, followed by upward vertical movement.
  • the end effector is configured to manipulate mold plates of an injection mold.
  • the end effector is configured to manipulate mold plates of a blow mold.
  • the robotic end effector comprises an auxiliary retainer, the auxiliary retainer for engaging a mandrel associated with a blow molding machine.
  • the first and second retainers are positioned at a first angular orientation
  • the auxiliary retainer is positioned at a second angular orientation, offset from the first angular orientation.
  • Robotic end effectors in accordance with this disclosure may include the above features in any operable combination.
  • An example method of manipulating a molding tool in a plastic molding system comprises: moving a robot to the molding tool, and wherein the molding tool is a mold installed at a press; matingly engaging a connector on a first plate of the mold and a connector on a second plate of the mold with an end effector of the robot; removing the mold from the press.
  • matingly engaging a connector comprises interlocking a cleat.
  • matingly engaging a connector comprises interlocking a set of jaws with a corresponding slot.
  • matingly engaging a connector comprises moving the end effector horizontally toward the mold, followed by moving the end effector vertically upwards.
  • the mold is an injection mold.
  • the mold is a blow mold.
  • the method comprises picking up a second tool with an auxiliary end effector on the robot.
  • the second tool is a mandrel associated with a blow mold station.
  • the second tool is a vessel.
  • Plastic molding methods in accordance with this disclosure may include the above features in any operable combination.
  • An example plastic molding system comprises: a plurality of process stations, operable to perform respective steps of a process for forming plastic molded articles; a plurality of tools for installation at respective process stations to perform the respective steps; a robot mounted above the process stations on a movable support, the robot having an end effector configured to matingly engage at least one of the tools to install the at least one of the tools at a process station or remove the at least one of the tools from a process station.
  • the plastic molding system comprises a plurality of interchangeable end- of-arm devices for installation to the robot, each the end-of arm device having an end effector configured to matingly engage a corresponding tool to lift the corresponding tool and install the corresponding tool at a process station or remove the corresponding tool from a process station.
  • the robot is movable on a frame along two horizontal axes.
  • the robot is movable along a vertical axis.
  • the robot comprises a wrist joint rotatable about a vertical axis to rotate an end-of-arm device installed to the robot.
  • each one of the end-of-arm devices comprises a releasable coupling for installation of the end-of-arm device to the robot.
  • the process stations comprise stations for performing steps of a plurality of different types, using tools of a plurality of different types, and wherein each the end effector is configured to matingly engage tools of a corresponding type.
  • the process stations comprise injection molding stations, and wherein the tools comprise mold assemblies for use at the injection molding stations.
  • the process stations comprise blow molding stations and wherein the tools comprise mold assemblies for use at the blow molding stations.
  • the end-of-arm devices comprise an end-of-arm device with an end effector for matingly engaging an injection mold assembly, and an end-of-arm device with an end effector for matingly engaging a blow mold assembly.
  • the plastic molding system comprises a storage rack accessible by the robot, the storage rack configured to hold the end-of-arm devices so that the robot can lock with any selected one of the end-of-arm devices at the storage rack.
  • the robot is operable to lift each of the tools using a corresponding end effector of an end-of-arm device.
  • Plastic molding systems in accordance with this disclosure may include the above features in any operable combination.
  • An example tool change system for a plastic molding system having a plurality of process stations comprises: a robot mounted above the process stations and movable to each of the process stations; a plurality of interchangeable end-of-arm devices for installation to the robot, each the end-of-arm device having a releasable coupling to secure the end-of-arm device to the robot; an end effector on each of the end of arm devices, each the end effector configured to matingly engage a corresponding tool for installing the corresponding tool at or removing the corresponding tool from a process station.
  • the robot is movable on a frame along two horizontal axes.
  • the robot is movable along a vertical axis.
  • the robot comprises a wrist joint rotatable about a vertical axis to rotate an end-of-arm device installed to the robot.
  • each one of the end-of-arm devices comprises a releasable coupling for installation of the end-of-arm device at the robot.
  • the process stations comprise stations for performing steps of a plurality of different types, using tools of a plurality of different types, and wherein each the end effector is configured to matingly engage tools of a corresponding type.
  • the process stations comprise injection molding stations, and wherein the tools comprise mold assemblies for use at the injection molding stations.
  • the process stations comprise blow molding stations and wherein the tools comprise mold assemblies for use at the blow molding stations.
  • the end-of-arm tools comprise an end-of-arm device with an end effector for matingly engaging an injection mold assembly, and an end-of-arm device with an end effector for matingly engaging a blow mold assembly.
  • the tool change system comprises a storage rack accessible by the robot, the storage rack configured to hold the end-of-arm devices so that the robot can lock with the coupling of any selected one of the end-of-arm devices at the storage rack.
  • the robot is operable to lift each the tool using a corresponding end effector of an end-of-arm device.
  • Tool change systems in accordance with this disclosure may include the above features in any operable combination.
  • FIG. 1 is a top view of a plastic molding system
  • FIG. 2 is an isometric view of the plastic molding system of FIG. 1;
  • FIG. 3 A is an isometric view of a shaping station of the plastic molding system of FIG. 1;
  • FIG. 3B is an enlarged cross-sectional view of a connector of the shaping station of FIG. 3 A;
  • FIG. 4A is a sectional view of a shaping station of the plastic molding system of FIG. 1;
  • FIG. 4B is an exploded view of a blow mold assembly of the blow-molding station of FIG. 4A;
  • FIG. 5 A is an isometric view of a mandrel at the shaping station of FIG. 4A;
  • FIG. 5B is an isometric view of a stretch rod at the shaping station of FIG. 4A;
  • FIG. 6 is an isometric view of a vessel of the plastic molding system of FIG. 1;
  • FIG. 7 is an isometric view of the plastic molding system of FIG. 1 showing a gantry frame and an automatic tool change robot;
  • FIGS. 8A-8C are isometric views of an end of arm tool of the automatic tool change robot of FIG. 7, showing details of end effectors;
  • FIG. 9 is an isometric view of the automatic tool change robot of FIG. 7, and showing a pickup sequence of movements;
  • FIG. 10 is an isometric view of the plastic molding system of FIG. 1 showing a gantry frame and an automatic tool change robot;
  • FIGS. 11 A-l 1C are isometric and side views of an end of arm tool of the automatic tool change robot of FIG. 10, showing details of a first end effector;
  • FIG. 1 ID is an isometric view of the end of arm tool of FIGS 11 A-l 1C, showing details of a second end effector;
  • FIG. 1 IE is a top view of the second end effector of FIG. 1 ID;
  • FIG. 1 IF is an isometric view of another end of arm tool
  • FIG. 11G is an isometric view of another end of arm tool
  • FIG. 11H is an isometric view of another end of arm tool
  • FIG. 1 II is an isometric view of another end of arm tool
  • FIG. 12 is an isometric view of the automatic tool change robot of FIG. 10, and showing a pickup sequence of movements;
  • FIG. 13A is a partial isometric view of the plastic molding system of FIG. 1 depicting a tool change cart;
  • FIG. 13B is a top plan view of the plastic molding system of FIG. 13 A, showing a holding area;
  • FIG. 14 is schematic diagram of a control system of the plastic molding system of FIG. 1;
  • FIG. 15 is a schematic view of data structures of the control system of FIG. 14;
  • FIGS. 16-17 are flow charts depicting a plastic molding method
  • FIG. 18 is an isometric view of another molding system
  • FIG. 19 is an isometric view of a frame of the molding system of FIG. 18;
  • FIG. 20 is a partially exploded isometric view of a beam of the frame of FIG. 19;
  • FIGS. 21-22 are isometric views of a beam of the frame of FIG. 19;
  • FIGS. 23-24 are isometric views of a carriage of the molding system of FIG. 18;
  • FIG. 25A is an isometric view of a robot of the molding system of FIG. 18;
  • FIG. 25B is an enlarged isometric view of a portion of the robot of FIG. 25B;
  • FIG. 26 is a side view of the molding system of FIG. 18; and
  • FIG. 27 is a top view of the molding system of FIG. 18.
  • FIGS. 1-2 depict top plan and isometric views, respectively, of an example plastic molding system 100 for producing plastic molded articles.
  • plastic molding system 100 is capable of molding articles through a sequence of processing operations.
  • system 100 provides flexibility to produce articles of a variety of types.
  • system 100 can produce articles of varying shapes, sizes, colours and material composition.
  • Plastic molding system 100 includes a plurality of process stations.
  • the stations include groups of stations that are each operable to perform the same type of processing operation.
  • the depicted embodiment comprises a plurality of dispensing stations 102-1, 102-2 (individually and collectively, dispensing stations 102), a plurality of shaping stations 104-1 through 104-8 (individually and collectively, shaping stations 104), a plurality of secondary shaping stations 106-1, 106-2 (individually and collectively, shaping stations 106), and a plurality of conditioning stations 108-1, 108-2 (individually and collectively, conditioning stations 108).
  • the depicted embodiment comprises two dispensing stations 102, eight shaping stations 104, two shaping stations 106 and two conditioning stations 108. However, any number of stations of each type may be present, and one or more of the foregoing types of stations may be omitted.
  • Each of the dispensing stations 102 is operable to perform a dispensing operation, namely, producing an output of molding material for use in subsequent operations.
  • Each of the shaping stations 104 is operable to perform a primary shaping operation.
  • each station 104 may include an injection mold for performing an injection molding operation.
  • Each one of shaping stations 106 is operable to perform a secondary shaping operation.
  • each one of shaping stations 106 include a blow mold for re-shaping an injection molded article into a finished shape.
  • dispensing stations 102 comprise extruders for producing a flow of molten plastic molding material such as PET from a solid (e.g. pelletized) feedstock; shaping stations 104 are injection molding stations for producing blanks known as preforms to be subsequently re-shaped into containers such as beverage containers; and shaping stations 106 are blow molding stations for re-shaping the preforms.
  • molten plastic molding material such as PET from a solid (e.g. pelletized) feedstock
  • shaping stations 104 are injection molding stations for producing blanks known as preforms to be subsequently re-shaped into containers such as beverage containers
  • shaping stations 106 are blow molding stations for re-shaping the preforms.
  • Blow molding operations typically require blanks to be at elevated temperature for re-forming. Accordingly, blanks may be processed at conditioning stations 108 to heat the blanks prior to shaping at stations 106.
  • dispensing stations 102 are operable to dispense a range of possible molding materials. For example, the dispensing stations may output molding materials having different colours, compositions, or other properties. Dispensing stations 102 may be configured to output molding material in discrete quantities, which may be referred to as doses.
  • different shaping stations 104 and different shaping stations 106 may include molds of different sizes or shapes.
  • system 100 may be capable of concurrently producing molded articles of a number of different types, with each specific type of article corresponding to a combination of a type and quantity of molding material from a dispensing station 102, a shape and size of an injection molded article from a shaping station 104, and a shape and size of a finished article from a shaping station 106.
  • FIG. 1 depicts a top plan view of molding system 100.
  • Stations of system 100 are positioned adjacent a transportation system, namely, a central track 101. In-progress and completed articles can be moved between stations along track 101.
  • Each article produced using system 100 is processed at a combination of a specific dispensing station 102, a specific shaping station 104, a specific shaping station 106 and a specific conditioning station 108.
  • Each unique combination may correspond to a unique type of molded article, and types may differ from one another in shape, size, colour, and material type, among other characteristics.
  • Each dispensing station 102 and shaping station 104, 106 includes tooling specific to an operation to be performed at the respective station.
  • each dispensing station 102 includes a dispenser barrel containing a particular type of molding material.
  • Each shaping station 104 includes a mold for forming an article of a particular shape by injection molding.
  • Each shaping station 106 includes a mold for forming an article of a particular shape by blow molding.
  • Tooling at stations 102, 104, 106 is removable. That is, tooling is capable of rapid installation to or removal from a station.
  • a station may be reconfigured by installation of new tooling.
  • a dispensing station 102 may be reconfigured to dispense a different type of molding material by removal of a first dispenser barrel containing a first material and installing a second dispenser barrel containing a second molding material.
  • a shaping station 104 may be reconfigured by removing a mold for producing articles of a first size and shape, and replacing it with a mold for producing articles of a second size and shape.
  • molds for articles of different shapes may be swapped at a shaping station 106.
  • System 100 may include an enclosure 200.
  • Enclosure 200 is omitted from FIG. 1.
  • Enclosure 200 includes barriers (e.g. walls) preventing unauthorized access to system 100 by personnel.
  • System 100 further includes a frame 202.
  • frame 202 can support a robot above stations 102, 104, 106 for manipulation (e.g. installation and removal of tooling).
  • Frame 202 may be constructed integrally with enclosure 200.
  • frame 202 may be a discrete structure separate from enclosure 200.
  • frame 202 includes two frame sections 202-1 and 202-2.
  • Each of the frame sections may support a separate robot.
  • the frame sections may be positioned above different stations, such that a robot associated with each frame section is operable to interact with a subset of stations within system 100.
  • more or fewer frame sections may be present.
  • Enclosure 200 includes one or more tooling portals 204 for permitting passage of tooling into or out of enclosure 200.
  • two tooling portals 204 are provided, proximate frame sections 202-1, 202-2, respectively, and positioned so that the robot on each frame section can access tooling provided by way of the corresponding portal.
  • Tooling carts 206 are provided for transporting tooling to or away from tooling portals 204. As will be described in greater detail, each tooling cart 206 may engage (e.g. interlock) with a feature proximate a tooling portal 204, such that tooling on the cart 206 can be easily registered to a spatial datum point in system 100. Such spatial registration may ease automated manipulation of tooling.
  • FIG. 3 A provides a detailed view of an example shaping station 102, with tooling installed.
  • shaping station 102 is a plastic injection molding station.
  • the station includes a press 210, which is operable to reciprocate a pair of platens 212 between a closed position (shown), for molding of articles, and an open position, for removal of molded articles or tooling, or installation of tooling.
  • press 210 includes a mechanical linkage 214 driven by a motor (not shown).
  • a mechanical linkage 214 driven by a motor (not shown).
  • other types of press may be used, such as hydraulic presses.
  • a mold assembly 216 is installed to platens 212.
  • the mold assembly 216 includes multiple components for defining the core and cavity of a mold.
  • the “core” refers to mold components which, during molding, define interior surfaces of a molded article
  • the “cavity” refers to mold components which, during molding, define exterior surfaces of the molded article.
  • mold assembly 216 includes a plurality of mold cavity plates 218 and a mold core assembly 220.
  • Mold core assembly 220 is received in a cavity (not shown) defined by cavity plates 218, such that the core assembly and cavity plates cooperatively define a mold.
  • Mold core assembly 220 is configured to interlock with cavity plates 218, such that when cavity plates 218 abut one another in a closed (molding) position, mold core assembly 220 cannot move relative to the cavity plates 218.
  • Each cavity plate 218 is releasably coupled to a respective platen 212 of press 210. When so coupled, cavity plates 218 move with platens 212 so that the platens and cavity plates are moved towards and away from one another in a reciprocating stroke.
  • Cavity plates 218 may be retained to platens 212 by suitable releasable retaining mechanism.
  • An example retaining mechanism is schematically depicted in FIG. 3B.
  • retaining mechanism 230 includes a stud 232 and a socket 234 which can selectively interlock with stud 232.
  • stud 232 is part of cavity plate 218 and socket 234 is part of platen 212.
  • Stud 232 may, for example, be threaded to cavity plate 218.
  • Socket 234 may be a recess cut into platen 212 or an insert attached (e.g. threaded) to platen 212.
  • socket 234 may instead be part of cavity plate 218 and stud 234 may instead be part of cavity plate 218.
  • Stud 232 has inner and outer flanges 236, defining a channel 238 therebetween.
  • Socket 234 has an opening sized to receive stud 232, and a gripping device 240.
  • Gripping device 240 is configured for reception in channel 238, in interlocking engagement with flanges 236.
  • Gripping device 240 is movable between engaged and disengaged states. In the disengaged state, gripping device 240 clears flanges 236 of stud 232 such that stud 232 may be freely inserted in or withdrawn from socket 234. In the engaged state, gripping device interlocks with stud 232, preventing stud 232 from being withdrawn from socket 234.
  • gripping device 240 comprises a series of balls 242 and a movable locking collar 244.
  • locking collar 244 holds balls 242 against channel 238.
  • Balls 242 bear against the distal flange 236 of stud 232, urging stud 232 (and cavity plate 218) against platen 212.
  • locking collar 244 is withdrawn, allowing balls 242 to shift away from stud 232.
  • mold assembly 216 comprises one or more handling devices for allowing the mold assembly to be engaged and manipulated by a robotic tool.
  • the handling devices comprise a pair of cleats 248 mounted to sides of cavity plates 218. Cleats 248 are positioned on an outward-facing surface of cavity plates 218, such that the cleats may be accessed while mold assembly 216 is installed to press 210.
  • cleats 248 are generally hook-shaped, to interlock with a mating cleat when the mating cleat is moved upwardly.
  • Cleats 248 are fastened (e.g., bolted) to the cavity plates such that the entire weight of mold assembly 216 can be supported by cleats 248 in order to move the mold assembly.
  • cleats 248 define an upwardly -tapering seat 249 which receives the mating cleat.
  • Cleats 248 may interlock with mating cleats as the weight of mold assembly 216 urges the mating cleats against the tapering seat 249. Thus, locking may occur passively, without operation of any actuators. Alternatively or additionally, locking devices may be provided, such as locking pins.
  • valve of retention control line 246 may be selectively opened in response to a signal from a controller.
  • the controller may be operated to coordinate opening of the valve and thus, releasing of the stud 232 and cavity plate 218 with engagement by a robotic tool.
  • FIGS. 4A-4B depict details of components of a shaping station 106.
  • Shaping station comprises a press 250 with opposing platens 252.
  • a mold assembly 254 is installed to press 250.
  • the mold assembly 254 is a blow mold. While installed to press 250, mold assembly 254 may be used to re-shape injection-molded articles (e.g., bottle preforms) from a shaping station 104 into finished articles (e.g. bottles or other similar containers) by blow molding.
  • injection-molded articles e.g., bottle preforms
  • finished articles e.g. bottles or other similar containers
  • Mold assembly 254 includes a plurality of cavity plates 260 and a base plate 262. Cavity plates 260 and base plate 264 mate to one another to cooperatively define a blow mold in the desired final shape of the articles to be molded. Cavity plates 260 have a cylindrical outer surface and mount to flat platens 252 of press 250 by way of adaptor plates 266.
  • Adaptor plates 266 may be attached to platens 252 using suitable fasteners e.g. bolts.
  • Cavity plates 260 are releasably connected to adaptor plates 266 by releasable retaining mechanisms 268.
  • Releasable retaining mechanisms 268 are selectively operable to lock cavity plates 260 to adaptor plates 266, or to release cavity plates 260 from adaptor plates 266, in response to a control signal.
  • releasable retaining mechanisms 268 may be substantially identical to retaining mechanisms 230.
  • Cavity plates 260 may be moved by platens 252 in a reciprocating stroke, between a closed position in which the cavity plates 260 abut one another to define a mold, and an open position in which the cavity plates 260 are withdrawn from one another to permit removal of finished articles.
  • base plate 264 While cavity plates 260 are in the closed position, base plate 264 is received in a cavity cooperatively defined by the cavity plates in order to define part of the mold. Base plate 264 is captive within the cavity. That is, base plate 264 cannot be removed from the cavity while cavity plates 260 are in the closed position.
  • Cavity plates 260 have a plurality of handling studs 270 projecting outwardly from an exterior (non-molding) surface. Handling studs 270 are configured to be engaged by a robotic handling tool. An enlarged top view of an example handling stud 270 is shown in FIG. 4C. As depicted, each handling stud has a main body 272, and an extension with a flange 274. A seat 276 is defined between the main body 272 and the flange 274, such that a hook may be placed on the handling stud 270 and retained in the seat 276.
  • System 100 includes one or more mandrels 280, each associated with one or both of a shaping station 106 and a conditioning station 108.
  • FIG. 5A depicts an example mandrel 280.
  • Each mandrel 280 is for handling articles to be conditioned (e.g. heated) at a conditioning station 108, molded (re-shaped) at shaping station 106 (e.g. bottle preforms from shaping stations 104), and for removing articles after such molding, or any combination thereof.
  • a mandrel 280 may be used to pick up an in-progress article, carry the article to a conditioning station 108 for heating, then carry the in-progress article to a shaping station 106 for molding and subsequently remove the finished article.
  • Each mandrel 280 is sized and configured according to characteristics of articles to be handled and molding processes to be performed on such articles.
  • Each mandrel 280 has an end surface 282 configured to abut an article to be molded.
  • the article may be retained against the end surface 282 by application of vacuum pressure.
  • end surface 282 may be an annular surface for abutting engagement with a corresponding annular closure section of a container blank or preform, and vacuum pressure may be applied to the interior of the blank or preform.
  • Different mandrels may be required to interface with articles of different shapes and sizes.
  • Mandrels 208 may therefore need to be changed along with changes of mold assemblies 216 or 254.
  • Each mandrel 280 has one or more handling rings 286.
  • the handling rings 286 are generally annular structures extending circumferentially around the exterior of mandrels 280.
  • handling rings 286 are grooves, sized to receive retainers of a robotic tool.
  • handling rings 286 may be protruding ridges, sized to be received in corresponding grooves in a robotic tool.
  • System 100 may further include stretch rods 281 associated with shaping stations 106.
  • An example stretch rod is depicted in FIG. 5B.
  • Stretch rods 281 are generally cylindrical, and may be inserted into an article to exert pressure on a wall of an article during a stretch-blow molding operation at a shaping station 106.
  • molding material is transported along track 101 in vessels 290.
  • An example vessel 290 is shown in FIG. 6.
  • Each vessel has an internal cavity in which molding material can be received, and a gate opening 292 through which molding material can be transferred into or out of the vessel 290.
  • Each vessel 290 further includes one or more handling rings 294.
  • the handling rings 294 are generally annular structures extending circumferentially around the exterior of vessels 290. In the depicted embodiment, handling rings 294 are grooves, sized to receive retainers of a robotic tool. Alternatively, handling rings 294 may be protruding ridges, sized to be received in corresponding grooves in a robotic tool.
  • FIG. 7 is an isometric view of a portion of molding system 100, showing details of frame section 202 1
  • frame section 202-1 provides support for a robot assembly and permits movement of the robot assembly relative to the stations of molding system 100, such that the robot can manipulate (e.g., move, install and remove) tooling of the stations.
  • Frame section 202-1 includes longitudinal rails 304.
  • Longitudinal rails 304 are positioned atop enclosure 200 and may be directly mounted to the enclosure, or to separate support columns.
  • One or more cross-beams 306 may extend between longitudinal rails 304 to provide support. As depicted, two longitudinal rails 304 are present. However, in other embodiments, more or fewer rails may be provided.
  • a transverse rail 308 extends between longitudinal rails 304.
  • Transverse rail 308 is supported proximate its ends by stanchions 310.
  • Each stanchion 310 is fixed to transverse rail 308 and is mounted to a respective longitudinal rail 304.
  • the stanchions are movable along the longitudinal rails.
  • the stanchions may slide on longitudinal rails 304, or the stanchions may be wheeled, such that they can roll along longitudinal rails 304.
  • One or more of stanchions 310 may be equipped with a drive unit, such as an electrical motor, for driving movement along longitudinal rails 304.
  • movement of stanchions 310 may be externally-driven, such as by way of a chain drive.
  • the drive unit may be equipped with a suitable encoder configured to provide a signal indicative of the position of stanchions 310 along rails 304.
  • a robot 312 is mounted to transverse rail 308.
  • the robot 312 is mounted by way of a carriage 314.
  • Carriage 314 is movable along transverse rail 308.
  • the carriage may be slidable along transverse rail 308, or may be wheeled, such that it can roll along transverse rail 308.
  • Carriage 314 may be equipped with a suitable drive unit, such as an electric motor mounted to the carriage, or an external drive such as a chain drive.
  • the drive unit may be equipped with a suitable encoder configured to provide a signal indicative of the position of carriage 314 along transverse rail 308.
  • a three-dimensional spatial coordinate system may be defined within molding system 100. As depicted in FIG. 7, the coordinate system has a horizontal x-axis parallel to the longitudinal rails 304 and a horizontal y-axis parallel to the transverse rail 308, and a vertical z-axis.
  • Robot 312 extends downwardly from carriage 314, parallel to the z-axis.
  • the robot 312 has an end of arm tool 316 at its distal end.
  • the end of arm tool 316 may be raised or lowered along the z axis, by movement of robot 312 relative to carriage 314, or by extension or retraction of robot 312.
  • FIGS. 8A-8C depict details of end of arm tool 316.
  • End of arm tool 316 has first and second end effectors 318, 320. End effectors 318, 320 are for engaging and manipulating a mold assembly 216 and a vessel 290, respectively.
  • End effector 318 comprises a plate 322 and a pair of retainers 324 rigidly fixed to the plate. Retainers 324 converge downwardly towards one another and define a downwardly-tapering seat 326 between the retainers. Retainers 324 and seat 326 are sized for interlocking reception in the tapers of cleats 248. Retainers 324 and cleats 248 are capable of bearing the weight of a mold assembly 216, such that the mold assembly can be lifted using end effector 318.
  • End effector 320 comprises a base block 328 rigidly fixed to the body of robot 312.
  • Two pairs of retainers 330 extend from base block 328.
  • the retainers 328 are arranged in horizontally- opposed pairs and are pivotable on base block 328, such that each pair of retainers 330 can be opened and closed, i.e., so that the distance between retainers of a pair can be increased and decreased.
  • Retainers 330 are sized and spaced so that, when open, a vessel 290 can be received between the retainers and, when closed, the vessel 290 can be retained by the retainers.
  • Vertical spacing between the pairs of retainers 330 corresponds to vertical spacing between handling rings 294 of vessel 290, such that each pair of retainers is received within or against a handling ring 294 and the weight of vessel 290 is borne by contact between retainers 330 and handling rings 294.
  • a vessel 290 may be securely engaged and lifted by retainers 330, when closed.
  • End of arm tool 316 is attached to the main body of robot 312 at a pivotable joint, referred to as a wrist joint 332.
  • Wrist joint 332 allows rotation of end of arm tool about a vertical axis, such that each of end effectors 318, 320 can be oriented in any horizontal direction to face a tool to be manipulated.
  • wrist joint 332 provides a single degree of freedom. That is, wrist joint permits movement on a single axis, namely, rotation about a vertical axis. As will be apparent, such a joint may be less complex and less expensive than joints with multiple degrees of freedom.
  • a drive unit 334 is provided to drive rotation of end of arm tool 316 about wrist joint 332.
  • drive unit 334 is an electric motor, geared to wrist joint 332.
  • end effector 318 interlocks with cleats 248 by a sequence of movements.
  • End of arm tool 316 is moved to so that the vertical position of retainers 324 of end effector 318 is just below that of cleats 248.
  • End of arm tool 316 may be rotated about wrist joint 332 so that the end effector is oriented to face cleats 248.
  • Robot 312 is then moved horizontally towards mold assembly 216 and cleats 248, as shown by arrow I in FIG. 9, so that arms 324 are in registration with cleats 248.
  • End of arm tool 316 is then moved upwardly so that retainers 324 and cleats 248 interlock with one another.
  • End of arm tool 316 is moved to so that the vertical position of retainers 330 of end effector 320 is aligned with that of retaining rings 294. End of arm tool 316 may be rotated about wrist joint
  • Retainers 330 are opened to receive vessel 290 and robot 312 is moved horizontally towards vessel 290 as indicated by arrow III in FIG. 8C. Once vessel 290 is fully received between the pairs of retainers 330, the retainers close to retain the vessel 290. Closing of retainers 330 may be automated, for example, based on the spatial position of end of arm tool 316, or by activation of a sensor positioned between retainers 330. The dropoff sequence of vessel 290 is the reverse of the pickup sequence.
  • the robot 312 supported by frame section 202-1 is operable to access shaping stations 104 and vessels 290 proximate shaping stations 104.
  • FIG. 10 depicts details of frame section 202-2
  • Frame section 202-2 supports a second robot 338 operable to access shaping stations 106, to install and remove mold assemblies 316 and mandrels at shaping stations 106.
  • Frame section 202-2 comprises longitudinal rails 304.
  • Longitudinal rails 304 of frame section 202-2 are parallel to one another, but are vertically offset from one another. That is, one of the longitudinal rails 304 is positioned vertically higher than the other to provide clearance for equipment at stations 106.
  • Longitudinal rails 304 are supported on columns 340.
  • a transverse rail 308 is supported on longitudinal rails 304, supported by stanchions 310.
  • the stanchions 310 have unequal height corresponding to the vertical offset between longitudinal rails 304, such that transverse rail 308 is supported in a horizontal position.
  • Stanchions 310 are movable along longitudinal rails 304 and are driven, substantially as described above with reference to frame section 202-1. Thus, transverse rail 308 can be moved along the length of longitudinal rails 304.
  • Robot 338 is supported on transverse rail by a carriage 314, which is movable along transverse rail and driven substantially as described above with reference to frame section 202-1. Robot 338 can positioned at substantially any X-Y position by movement along longitudinal rails 304 and transverse rail 308.
  • Robot 338 is generally similar to robot 312 described above, except that robot 338 includes an end of arm tool 342 designed to install and remove and manipulate tooling at shaping stations 106.
  • End of arm tool 342 can be raised and lowered, for example, by extending or retracting robot 338 or by moving the robot relative to carriage 314.
  • End of arm tool 342 includes an end effector for engaging and manipulating mold assemblies
  • FIGS. 1 lA-11G depict end of arm tool 342 in greater detail. As shown in FIG. 11 A, end effector 344 is configured for engaging and manipulating mold assemblies 254 and end effector 346 is configured for engaging and manipulating mandrels 280.
  • End effector 344 is positioned at a first angular orientation on end of arm tool 342.
  • End effector 346 is positioned at a second angular orientation, offset from that of end effector 344.
  • the angular orientations of end effectors 344, 346 define directions in which robot 312 moves to engage a mold assembly 254 or a mandrel 280, respectively. That is, robot 312 is positioned such that the appropriate end effector faces tooling to be picked up, and then is moved to approach the tooling. The direction of this approach corresponds to the angular orientation of the end effector.
  • end effectors 344, 346 therefore provide clearance for equipment at shaping stations 106.
  • the angular orientations may be selected based on spatial constraints imposed by such equipment, so that the robot is able to engage any tooling by moving within the available space.
  • End effectors 344, 346 are positioned and oriented on end of arm tool 342 so that neither end effector interferes with tooling to be picked up using the other end effector.
  • end effector 344 is vertically offset downwardly from end effector 346. Because of the vertical and angular offset of the end effectors, end effector 344 can pick up a mold assembly 254 without the other end effector 346 interfering with the mold assembly.
  • end effector 346 can pick up a mandrel 280 without the other end effector 344 interfering with the mandrel 280. This clearance between end effectors 344, 346 is achieved while limiting the horizontal space occupied.
  • FIGS. 11B-11C depict details of end effector 344.
  • end effector 344 has a pair of opposing arms 348 extending from a base 350.
  • the base 350 is mounted to the body of end of arm tool 342 and maintains arms 348 substantially rigidly in position.
  • Arms 348 have a plurality of slots 352, each for receiving a corresponding one of handling studs 270 of mold assembly 254.
  • each arm has three slots 352-1, 352-2, 352-3.
  • the slots are positioned correspondingly to handling studs 270 on mold assembly 254.
  • Slots 352-1 and 352-2 are positioned at a leading edge of arm 248 and open laterally.
  • Slot 352- 3 is positioned at a bottom edge of arm 248 and opens downwardly. That is, a handling stud 270 may be received in each of slots 254-1, 254-2 by horizontal movement, and a handling stud 270 may be received in slot 352-3 by vertical movement, followed by horizontal movement.
  • Each slot defines a hook 354.
  • Arms 348 may be maneuvered so that handling studs 270 are positioned within slots 352. Arms 348 may then be moved to seat the handling studs 270 against the hooks 354. For example, in the depicted embodiment, upward vertical movement of arms 348 seats handling studs 270 against hooks 354. With handling studs 270 seated, hooks 354 retain the handling studs 270. Mold assembly 354 may therefore be lifted and stably transported using end effector 344 and handling studs 270. Slots 352-1, 352-2 receive and retain handling studs 270 on a first mold cavity plate 260 of mold assembly 254. Slot 352-3 receives and retains a handling stud 270 on the other mold cavity plate 260. Arms 248 hold mold assembly 254 in its closed position, in which cavity plates 260 retain base plate 262.
  • FIGS. 1 ID- 1 IE depict details of an example end effector 346.
  • End effector 346 has a body 360 and a set of jaws 362 pivotably mounted to the body.
  • Body 360 and jaws 362 define a slot 364 into which a mandrel 280 can be received.
  • Jaws 362 can pivot between a closed position (shown in FIG. 1 IE) and an open position. In the closed position, an opening between jaws 362 is less than a diameter of mandrel 280, such that the jaws can retain the mandrel in slow 364. In the open position, the distance between the jaws is larger than the diameter of mandrel 280, such that the mandrel can pass into slot 364.
  • Jaws 362 are biased to the closed position.
  • the jaws may be spring-biased.
  • Jaws 362 have outwardly-tapering cam surfaces 366.
  • the outer surface of mandrel 280 bears against cam surfaces 366 and urges jaws 362 towards their open position.
  • jaws 362 return to their closed position to retain the mandrel.
  • Jaws 362 also have inwardly -tapering cam surfaces 367 that face mandrel 280 when the mandrel is received in slot 364. The mandrel 280 can bear against cam surfaces 367 to force jaws to their open position.
  • jaws 362 and body 360 cooperatively define a profile that is complementary to mandrel 280. Specifically jaws 362 and body 360 interlock with retaining rings 286 of mandrel 280. Such interlocking prevents axial (i.e. vertical) movement of mandrel 280 relative to end effector 346.
  • End of arm tool 342 is rotatable relative to the body of robot 338. Specifically, the end of arm tool can be rotated about a vertical axis.
  • FIGS. 11F-11I depict end of arm tools 343 342’, 316’ and 345 which may be used additionally or alternatively to those described above.
  • End of arm tool 343, depicted in FIG. 1 IF includes an end effector 370 for manipulating a stretch rod 281.
  • the end effector 370 includes a set of jaws 372 which are generally similar to jaws 362 (FIGS. 11D-11E), but which are sized for reception and retention of stretch rod 281, which has a smaller outer diameter than that of mandrel 280.
  • End of arm tool 343 also includes a releasable coupling 347 for mounting the end of arm tool 343 to robot 312.
  • releasable coupling 347 may interlock with a corresponding coupling at robot 312 (e.g., at wrist joint 332) so that end of arm tool 343 is secured to the robot.
  • Releasable coupling 347 may be selectively released for removal of end of arm tool 343.
  • the coupling may be released to remove end of arm tool 343 from robot 312 and replace end of arm tool 343 with another end of arm tool.
  • Releasable coupling 347 may be actuated using any suitable mechanism.
  • releasable coupling 347 may be spring-loaded and may lock in response to engagement by robot 312.
  • releasable coupling 347 may be pneumatically or electrically (e.g. solenoid) actuated.
  • End of arm tool 342’ depicted in FIG. 11G, includes an end effector 320 and two end effectors 346.
  • the end effectors 346 are positioned on opposing sides of the end of arm tool 342’ and can be used to manipulate two different mandrels 280.
  • multiple conditioning stations 108 may be present such that it is desirable for robot 312 to concurrently handle multiple mandrels.
  • Such a configuration may allow for faster tooling changes at conditioning stations 108, relative to configurations with a single end effector 346.
  • mandrel changes at multiple conditioning stations 108 may be effected with less movement of robot 312.
  • Additional end effectors may be installed on other sides of the end of arm tool 342’.
  • an end effector 320 is positioned on another side of the end of arm tool.
  • End of arm tool 342’ also includes a releasable coupling 347 for locking the end of arm tool to robot 312 and selectively releasing the end of arm tool.
  • FIG. 11H depicts another end of arm tool 316’.
  • End of arm tool 316’ includes an end effector 318 for engaging and moving a mold assembly 216 (FIG. 3A) as described above with reference to FIGS. 8A-8B.
  • end of arm tool 316’ includes a single end effector. However, other end effectors, including end effectors of other types described herein, may be added.
  • End of arm tool 316’ is releasably mountable to robot 312 using a releasable coupling 347.
  • FIG. 1 II depicts another end of arm tool 345.
  • End of arm tool 345 includes an end effector 344 for engaging and moving a mold assembly 254 (FIG. 4B) as described above with reference to FIGS. 1 lA-11C.
  • End of arm tool 345 includes a releasable coupling 347 for selectively locking end of arm tool 345 to robot 312 and releasing end of arm tool 345 from robot 312.
  • the releasable couplings 347 on each of end of arm tools 343, 342’, 316’ and 345 may be substantially identical to one another. That is, each of the releasable couplings may be designed to interlock with a common type of corresponding coupling on robot 312. Accordingly, the end of arm tools may be interchanged with one another, such that robot 312 and the various end of arm tools define a system for handling a variety of tools within molding system 100.
  • the end of arm tools may be stored at a storage location (e.g., a rack) accessible by robot 312, and robot may lock to any selected one of the end of arm tools for picking up and moving a corresponding type of tool within the system.
  • a storage location e.g., a rack
  • robot may lock to any selected one of the end of arm tools for picking up and moving a corresponding type of tool within the system.
  • couplings 347 may be added to other end of arm tools described herein.
  • FIG. 12 depicts a pickup sequence of end effector 344 to engage a mold assembly 254.
  • Robot 338 is positioned vertically above the mold assembly 254 to be lifted and rotated to align with the mold assembly.
  • End of arm tool 342 is moved vertically down as indicated by arrow I in FIG 12, so that ahandling stud 270 is received in slot 352-3 and handling studs are positioned adjacent openings of slots 352-1, 352-2.
  • End of arm tool 342 is then moved horizontally as indicated by arrow II, so that a handling stud 270 is received in each of slots 352-1, 352-2 and the handling studs 270 are positioned in registration with the hooks 354 of each respective slot.
  • the end of arm tool 342 is then moved upwardly as indicated by arrow III, seating handling studs 270 against hooks 354 so that the hooks retain the handling studs (and thus, mold assembly 254).
  • Proximity sensors may be positioned on one or both of the mold assembly 254 and the end effector 344 to provide a signal confirming engagement of the mold assembly 254 by end effector 344. Mold assembly 254 may be released from platens 252 in response to the signal.
  • the dropoff sequence is the reverse of the pickup sequence.
  • a pickup sequence of end effector 346 to pick up a mandrel 280 is best shown in FIG. 1 ID.
  • End of arm tool 342 is positioned proximate mandrel 280 and moved so that jaws 362 are at the same height as retaining rings 286 of mandrel 280.
  • End of arm tool 342 is rotated so that slot 364 faces mandrel 280.
  • End of arm tool 342 is then moved horizontally as indicated by arrow I so that mandrel 280 is received in slot 364.
  • the mandrel bears against cam surfaces 366 of jaws 362 and forces the jaws into their open position. Once mandrel 280 is received in slot 364, the jaws return to their closed position.
  • End effector 346 interlocks with retaining rings 286 of mandrel 280 such that the weight of mandrel is supported by the end effector 346 and robot 338.
  • the mandrel may be released for support and transportation by the mandrel upon end of arm tool 342 reaching a defined interlock position.
  • release of the mandrel may be triggered by sensors such as proximity sensors that confirm engagement of the mandrel by end of arm tool 342.
  • the dropoff sequence is the reverse of the pickup sequence.
  • robots 312, 338 are operable to install a mold assembly 216, a mold assembly 254, a vessel 290 or a mandrel 280 (individually or collectively, “tools”) at shaping stations 102, shaping stations 104 (individually or collectively, “stations”) or transport track 101 and to remove tooling at stations or transport track 101 of molding system 100.
  • the robots may be used to remove a first tool from a station and replace it with a second, different tool. Removal and replacement of tools in this manner allows for rapid and easy reconfiguration of stations.
  • Tools to be installed may be transported from a remote location and placed in a holding area accessible by robots 312, 338. Likewise, tools removed may be placed in the holding area for subsequent re-installation or return to storage at the remote location.
  • FIGS. 13A-13B depict an example holding area 400 accessible by robot 312.
  • a separate holding area is provided for access by robot 338.
  • a single holding area may be provided.
  • Transport carts 404 may be used to carry tooling from a remote location to holding area 400.
  • Transport carts 404 may be motorized or manually-driven wheeled vehicles.
  • Each transport cart 404 has a table 406.
  • Tooling may be carried on pallets 408 supported on table 406.
  • pallets 408 are configured to hold tooling in a fixed, known location relative to a spatial datum.
  • Table 406 may include one or more rollers (not shown) for allowing pallets 408 to easily be moved atop the cart 404.
  • Table 406 has at least one guide 407, e.g. a raised edge. Pallets 408 may be justified against guide 407 so that the guide serves as a spatial datum for locating the pallets.
  • transport cart 404 interfaces with holding area 400 at a window 409.
  • Window 409 is sized to receive a pallet 408 carrying tooling so that the pallet can be transferred from transport cart 404 to holding area 400 through window 409.
  • Window 409 and cart 404 include interlock features. Specifically, cart 404 has one or more hooks that engage corresponding detents at window 409. Such engagement holds cart 404 at a known, fixed position at window 409.
  • Holding area 400 includes a conveyor device 410 and a storage rack 412.
  • Conveyor device 410 may be any suitable conveyor operable to move a pallet 408 along at least one direction.
  • the conveyor device includes a primary conveyor operable to move a pallet 408 in the x-direction and a secondary conveyor operable to move a pallet 408 in the y- direction.
  • Conveyor device 410 has a stop 414 that limits travel of pallet 408.
  • Conveyor device 410 advances pallet 408 into contact with stop 414, such that pallet 408 is maintained at a fixed, known location.
  • Pallet 408 has one or more nests 416 in which tooling may be held and maintained at a specific orientation.
  • the location and orientation of a specific tool can be determined based on the position of stop 414 and nests 416, so that robot 312 can move to and pick up the tool.
  • Tooling may be retrieved by robot 312 from a pallet 408 at conveyor device 410 and transferred to a station, to track 101 or to storage rack 412.
  • FIG. 14 depicts components of an example control system 500 for such automation.
  • the control system 500 includes controllers 502 for operating hardware at each station 104, 106, controllers 504 for moving and operating robots 312, 338 and a supervisory controller 506 for directing overall operation of system 100 and coordinating operation of robots 312, 338 and stations 102, 104, 106. Although one station controller 502 and one robot controller 504 is depicted in FIG. 14, a controller may be present for each station and each robot of station 100.
  • Supervisory controller 502 tracks production requirements and directs operation of components of system 100 based on the production requirements. For example, supervisory controller 502 may maintain records of article types and quantities to be produced, and may allocate ones of stations 102, 104, 106 to be used in fulfilment of such orders. In addition, supervisory controller 502 may maintain records of available tooling corresponding to specific article types. Supervisory controller 502 may direct specific tooling to be installed at stations in accordance to article types to be produced.
  • Supervisory controller 502 may maintain data structures as depicted in FIG. 15.
  • data structure 508 contains an identifier of each station within system 100, a station type (e.g. dispensing station 102, shaping station 104, shaping station 106), spatial location of the station (e.g. co-ordinates on an x-y-z grid), and an identifier of a tool installed at the station.
  • Data structure 510 includes an identifier of each tool, and one or more parameters defining characteristics of the tool.
  • the parameters may define the type of station the tool is to be installed at, and the size and shape of articles to be produced using the tool.
  • Data structure 510 may also include a spatial location of each respective tool (e.g. co-ordinates on an x-y-z grid). The spatial location may be identical to that of a corresponding station, if the tool is installed at the station, or the spatial location may correspond to a location within holding area 400.
  • Data in data structures 508, 510 may, for example, be received from an external data store or another controller over a network connection, and may be updated based on status messages and instructions sent between supervisory controller 506 and station controllers 502 and robot controllers 504.
  • Station controllers 502 communicate with supervisory controller 506 and receive instructions to coordinate production of parts. Instructions may include instructions to begin or stop running, or instructions to engage or release tools such as a mold assembly 216 or 254.
  • Station controllers 502 may include one or more press actuator outputs 512 for causing cycling of press 210 or 250 between open and closed positions. During production, station controllers 502 may automatically cause cycling of presses 210, 250 between open and closed positions. Station controllers 502 may also cause a press to open or close based on an explicit instruction from supervisory controller 506, e.g., for installation or removal of a tool.
  • Station controllers 502 may further include one or more tooling connector outputs 514 for causing engagement or releasing of connectors to tooling. Based on an instruction from supervisory controller 506, station controller 502 may selectively cause a tool to be released for removal by a robot 512, 538, or may selectively cause connectors to engage a tool during installation, so that the tool can be retained at the station. Such an instruction may, for example, be sent in response to robot 312, 338 reaching a position for tooling removal or installation.
  • Robot controllers 504 include position outputs 516, 518, 520 for controlling positioning of end of arm tools 316, 342 along the x, y and z axes, respectively.
  • Position output 516 controls drive of stanchions 510 along longitudinal rails 304.
  • Position output 518 controls drive of carriage 314 along transverse rails 308.
  • Position output 520 controls vertical movement of end of arm tools 316, 342, by extension of robots 312, 338 or by movement of robots 312, 338 relative to their respective carriages 314.
  • Robot controllers 504 further include a rotation output 522 for controlling rotation of end of arm tools 316, 342 about wrist joint 332.
  • Robot controllers 504 are operable to receive a message from supervisory controller 506 directing a robot to be moved to a specific location for pickup of a tool or for installation of a tool. In response to such instruction, the robot controllers 504 cause movement of the robot 312 or 338 to the specified location, and cause the robot to move to engage or release tools as described above.
  • FIGS. 16-17 depicts tool removal and installation in an example molding method 600.
  • molding is initiated at system 100.
  • Tooling is installed at some or all of shaping stations 104, 106, and molded articles are manufactured.
  • different tooling i.e. molds of different shapes, may be installed at shaping stations 104 and at shaping stations 106, so that multiple types of articles may be concurrently produced.
  • supervisory controller 506 identifies a station requiring a change of tooling, and a tool to be installed at that station, based on a production requirement and available tool information from data structure 510.
  • supervisory controller 506 sends a message to robot controller 504 identifying a location of the station requiring a change of tool. The location may be based on information from data structure 508.
  • the robot controller causes a robot 312 or 338 to be moved to a position proximate the station requiring a change of tool.
  • Supervisory controller 506 also sends a message to the station controller at the selected station, causing cycling to stop. If the station is a shaping station 104 and the tooling to be changed is a mold assembly 216, cycling is stopped with the press 210 in a closed position, such that the mold assembly 216 is in a closed position. Likewise, if the station is a shaping station 106 and the tooling to be changed is a mold assembly 254, cycling is stopped with the press 250 in a closed position so that the mold assembly 254 is also in a closed position.
  • robot controller 504 causes end of arm tool 316 or 342 to be moved in a tool pickup sequence corresponding to the tool to be picked up, i.e. corresponding to pickup of a mold assembly 216, a mold assembly 254, a mandrel 280 or a vessel 290.
  • a tool pickup sequence corresponding to the tool to be picked up, i.e. corresponding to pickup of a mold assembly 216, a mold assembly 254, a mandrel 280 or a vessel 290.
  • engagement of the tool by the end of arm tool 316 or 342 is detected.
  • an instruction is sent to station controller 502 to release tooling connectors. If the station is a shaping station 104 or a shaping station 106, and the tooling being removed is a mold assembly 216 or a mold assembly 254, station controller 502 is also instructed to open press 210, 250, so that the tool is free to be removed.
  • the robot 312 or 338 is moved, along with the picked-up tool, to holding area 400.
  • the tool is deposited at a specified location in the holding area, and at block 612, the robot’s coordinates at the drop-off location are stored in data structure 510 as the location of the tool.
  • a tool to be installed at a station is selected.
  • the tool may be selected as described above with reference to block 604.
  • robot controller 504 moves a robot 312 or 338 to the location of the selected tool, based on the location stored in data structure 510.
  • the location may, for example, be a location in holding area 400.
  • the robot 312 or 338 is moved in a tool pickup sequence to engage the selected tool. Engagement may be confirmed by a sensor at the tool, on end of arm tool 316, 342, or at holding area 400.
  • the robot 312 or 338 is moved to the station selected at block 604. If the tool to be installed is a mold assembly 216/254, the press 210/250 at the station is cycled to an open position to receive the tool.
  • the robot 312 or 338 is moved in a tool dropoff sequence corresponding to the type of tool to be installed.
  • the tool is placed in a position for engagement at the station.
  • Proper positioning of the tool may be confirmed based on positioning of the robot 312, 338 or by a sensor at the station.
  • supervisory controller 506 sends a signal to the station controller, causing connectors to engage and retain the tooling. Robot 312, 338 is then withdrawn.
  • station data in data structure 508 is updated to reflect the tool newly -installed at the station.
  • tool data in data structure 510 is updated to reflect the location of the tool.
  • supervisory controller 506 sends a signal to station controller 502 to resume cycling and production of articles.
  • removal of a tool at blocks 602-612 may be performed without immediately being followed by installation of a tool. That is, blocks 614-626 may be omitted. This may occur, for example, if production of articles at a particular station is completed, and there are no immediate requirements for further production at that station.
  • installation of a tool at blocks 614-626 may be performed without being immediately preceded by removal of a tool (blocks 602-612).
  • a station may be idle prior to installation of a tool.
  • removal of a tool from a station at blocks 602-612 and installation of a tool at blocks 614-626 may be performed without altering operation of other stations within system 100.
  • tooling may be interchanged to reconfigure production capabilities of system 100 within minimal downtime or lost productivity.
  • reconfiguration may be achieved with little or no involvement of human operators.
  • FIGS. 18-19 depict an example system 700, generally similar to system 100.
  • System 700 includes a robot 312 for installing and removing tooling at stations 102, 104, 106, 108.
  • a single robot 312 is capable of moving to any station within system 700 for manipulation of tooling.
  • Stations 102, 104, 106, 108 are omitted from FIG. 19 to show details of the robot 312 and associated support.
  • Robot 312 is supported on a frame 706 which includes a single longitudinal rail 708 and a transverse rail 712.
  • the longitudinal rail is supported by a set of columns 710.
  • the transverse rail 712 is secured at one end to longitudinal rail 710, and extends from the longitudinal rail in a cantilever.
  • Longitudinal rail 708 defines a track, and transverse rail 712 is mounted to the track such that the transverse rail is movable along the length of longitudinal rail 708, i.e. along the X axis.
  • Robot 312 is mounted to transverse rail 312 by way of acarriage 314.
  • the robot can be extended and retracted along the Z (i.e. vertical) axis, and the carriage is movable along the length of transverse rail 712, i.e. along the Y axis.
  • FIG. 20 depicts longitudinal rail 708 in greater detail.
  • Longitudinal rail 708 may be generally rectangular or I-shaped in cross-section and may have one or more flanges 714 projecting outwardly and extending along the length of the rail.
  • the flanges 714 may be engaged by bearing features of transverse rail 712 to guide motion of the transverse rail along the longitudinal rail.
  • one or more flanges 714 may interlock with transverse rail 712 and the transverse rail mail slide or roll along one or more flanges 714.
  • any of rails 708, 712 may be constructed in multiple sections.
  • FIG. 20 depicts a longitudinal beam 708 formed in two sections. The sections are shown offset from one another for illustration.
  • multi-section rails may be equipped with features for ensuring precise alignment of the sections.
  • a plate 716 is interposed between a first section 708-1 and a second section 708-2 of longitudinal rail 708, such that both sections may be joined or fastened (e.g. bolted) to the plate 716 and to one another.
  • a set of dowels 718 may also be provided, extending from one rail section for reception by a mating beam section.
  • transverse rail 712 may include multiple structural members interconnected by struts 720 so that the rail 712 can rigidly support the weight of robot 312.
  • Transverse rail 712 may include a coupling assembly 722 for retention of the transverse rail 712 to longitudinal rail 708 and for driving movement of the transverse rail 712 along longitudinal rail 708.
  • coupling assembly 722 includes a series of sliders 724 configured to slidably interlock with flanges 714 of longitudinal rail 708, and a drive roller 726 for rolling along a flange 714 of longitudinal rail 708.
  • the drive roller 726 is driven by a motor, such as an electric motor 728.
  • Electric motor 728 may be equipped with an encoder for reporting signals representative of rotation of the roller 726 (and thus, of movement and position of transverse rail 712 along the length of longitudinal rail 708).
  • Transverse rail 712 may also include a carriage drive system 730, for moving carriage 314 and robot 312 along the length of the transverse rail.
  • the carriage drive system includes a belt 732, to which the carriage may be attached.
  • the belt is driven by a motor, such as an electric motor 734, which is equipped with an encoder for reporting signals representative of movement of the belt 732, and thus, the movement and position of carriage 314 along the transverse rail 712.
  • FIGS. 23-24 depict carriage 314 in greater detail.
  • Carriage 314 has a main body 736, which is retained on transverse rail 712 by sliders 738 which slidably interlock with the rail.
  • Robot 312 comprises a downwardly -extending arm 740, slidably received by guide blocks 742 on the carriage.
  • the carriage also comprises a motor, such as an electric motor 744, configured to drive arm 740 upwardly and downwardly (i.e. along the Z-axis).
  • Motor 744 is equipped with an encoder for reporting signals representative of the movement and position of arm 740.
  • Carriage 314 may also include a locking device for holding arm 740 in a desired vertical position. In the depicted embodiment, the locking device is a pin 746.
  • the pin 746 is movable between a locking position in which it interlocks with arm 740 and a retracted position, in which the arm 740 is free to move.
  • a drive is provided for moving the pin 746 between positions.
  • the drive is an electric motor 748.
  • pin 746 may be driven by a solenoid or other suitable drive.
  • pin 746 is biased (e.g. spring-biased) to the locking position, and is retracted by operation of motor 748.
  • FIGS. 25A-25B depict robot 312 in greater detail.
  • FIG. 25B is an enlarged view of the region marked B in FIG. 25A.
  • Robot 312 has a tool carrier 331 at its bottom end , joined to the arm at a wrist joint 332.
  • Wrist joint 332 permits rotation of tool carrier 331 around the longitudinal axis of arm 740, i.e., around the Z axis.
  • Rotation at the wrist joint 332 is driven by a motor such as an electric motor 750, which may be equipped with an encoder to output signals representative of the movement and angular orientation of the wrist joint.
  • Tool carrier 331 has a coupling 334 for releasably locking with an end of arm tool.
  • the coupling may for example be pneumatically or electrically operated.
  • a tool identification device may also be mounted to robot 312.
  • the tool identification device is a camera 752.
  • the camera 752 is mounted to tool carrier 331, such that the camera can be rotated along with the tool carrier.
  • Camera 752 is positioned and configured to read identifying markings on tooling in system 700.
  • indicia such as bar codes, QR codes, number plates or the like may be attached to tooling.
  • the indicia may include serial numbers, asset tags or the like, which may be used to uniquely identify tooling and associated configuration information.
  • Robot 312 may use camera 752 to identify tooling prior to picking up the tooling for installation to or removal from a station within system 700.
  • identification may require camera 752 to be positioned in close proximity to tooling such that identifying indicia are positioned within a field of view 754 of the camera, as shown in FIG. 26.
  • Robot controller 514 may therefore include a calibration system for determining precise locations of system components.
  • robot controller 514 may be programmed with nominal positions of track 101 and each station 102, 104, 106, 108.
  • the controller may be capable of adjusting such positions based on measured correction factors.
  • the correction factors may, for example, be parametrically defined offsets, such that the position of each component within system is defined by a combination of a nominal position and a 3- dimensional (X-Y-Z) correction factor relative to the position of track 101.
  • Track 101 and each station 102, 104, 106, 108 may be equipped with a position marker 754 for determination of correction factors.
  • each position marker is a rectangular steel plate with dimensions larger than the largest positional tolerance associated with the installation of system 100, 700.
  • a probe (not shown) may be installed to robot 312 to precisely measure the location of each position marker 754.
  • the probe is an inductive probe.
  • probes may be optical or laser probes, magnetic probes, or any other suitable type.
  • the robot 312 In order to determine each correction factor, the robot 312 is moved to the nominal X-Y position of the respective position marker 754 and extended downwardly until the probe contacts the position marker.
  • the Z-offset is determined based on the Z-co-ordinate of robot 312 when the position marker is contacted, relative to the co-ordinate expected for the marker’s nominal position.
  • the robot is then moved in the X direction until an edge of the position marker 754 is detected.
  • the X-offset is determined based on the robot’s X co-ordinate when the edge is detected, relative to the co-ordinate expected for the marker’s nominal position.
  • the Y-offset may then be determined by moving robot 312 in the Y-direction until an edge of the position marker 754 is located, and defining the offset based on the Y co-ordinate of robot 312, relative to the co-ordinate expected for the marker’s nominal position.
  • the positions of stations 102, 104, 106, 108 may be defined relative to that of track 101. Accordingly, a correction factor may be determined for track 101, then for each of stations 102, 104, 106, 108.
  • the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements.
  • the terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

L'invention concerne un système de moulage de plastique qui comprend un ensemble moule ayant des éléments de liaison de manutention externes. L'ensemble moule est installé sur une presse configurée pour recevoir l'ensemble moule pour produire des articles en plastique. Un robot est monté sur un cadre au-dessus de la presse, le robot a un effecteur final pour lever l'ensemble moule par mise en prise avec les éléments de liaison de manutention. Le robot est mobile par rapport à la presse pour installer l'ensemble moule sur la presse et pour retirer l'ensemble moule de la presse.
PCT/CA2022/050915 2021-06-17 2022-06-08 Appareil et procédé de changement d'outil de moulage WO2022261751A1 (fr)

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US202163211725P 2021-06-17 2021-06-17
US63/211,725 2021-06-17

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5670925A (en) * 1979-11-15 1981-06-13 Hitachi Ltd Automatic die exchange system for injection molding machine
JPS5981122A (ja) * 1982-11-02 1984-05-10 Nissei Plastics Ind Co 金型搬送装置
JPS59129128A (ja) * 1983-01-14 1984-07-25 Fuji Electric Corp Res & Dev Ltd 横形射出成形機の金型自動交換装置
US5249947A (en) * 1990-03-22 1993-10-05 Fanuc Ltd. Injection molding machine having an automatic mold changer
JPH081709A (ja) * 1994-06-21 1996-01-09 Komatsu Raito Seisakusho:Kk 自動成形装置
CN109732027A (zh) * 2019-02-27 2019-05-10 温州大学 一种多工位冷墩机自动换模装置

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5670925A (en) * 1979-11-15 1981-06-13 Hitachi Ltd Automatic die exchange system for injection molding machine
JPS5981122A (ja) * 1982-11-02 1984-05-10 Nissei Plastics Ind Co 金型搬送装置
JPS59129128A (ja) * 1983-01-14 1984-07-25 Fuji Electric Corp Res & Dev Ltd 横形射出成形機の金型自動交換装置
US5249947A (en) * 1990-03-22 1993-10-05 Fanuc Ltd. Injection molding machine having an automatic mold changer
JPH081709A (ja) * 1994-06-21 1996-01-09 Komatsu Raito Seisakusho:Kk 自動成形装置
CN109732027A (zh) * 2019-02-27 2019-05-10 温州大学 一种多工位冷墩机自动换模装置

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