Part transfer system

Abstract

The name of the invention is a part transfer system. The part transfer system includes a movable support, a plurality of arms coupled to the movable support, and an end effector coupled to an end of each of the plurality of arms. The end effector includes a body and a plurality of partitions each coupled to the body. The plurality of partitions divide the body into a plurality of zones. The end effector includes a plurality of vacuum ports each in fluid communication with one of the plurality of zones. The part transfer system further includes a vacuum source in fluid communication with at least one of the plurality of vacuum ports. Each of the plurality of vacuum ports is configured to draw fluid from the plurality of zones to establish a vacuum between the end effector and a part engaged with the end effector to secure the part to the end effector.

Description

Technical Field

[0001] This disclosure generally relates to a manufacturing system, and more specifically, to a parts transfer system. Background Technology

[0002] During the manufacturing of some mechanical systems (such as aircraft), some parts may need to be moved from one placement location to another. For this purpose, the manufacturing system may pick up a part from one location and move it to another. The manufacturing system may include end effectors capable of holding the part. These end effectors can then be moved to transfer the part to another location. Summary of the Invention

[0003] This disclosure describes a part transfer system and method for transferring parts (such as longitudinal beams or other polymer composites) from one location (such as a former) to another location (such as a mating pallet). The part transfer system disclosed herein allows for the transfer of parts of different sizes (such as longitudinal beams) from one location to another without significant changes to the system, thereby reducing manufacturing costs and time.

[0004] In one aspect of this disclosure, a part transfer system includes a movable support, a plurality of arms coupled to the movable support, and an end effector coupled to each of the plurality of arms. The end effector includes a body and a plurality of partitions, each coupled to the body. The partitions divide the body into a plurality of zones. The end effector includes a plurality of vacuum ports, each in fluid communication with one of the plurality of zones. The part transfer system further includes a vacuum source in fluid communication with at least one of the plurality of vacuum ports. Each of the plurality of vacuum ports is configured to draw fluid from the plurality of zones to establish a vacuum between the end effector and a part engaged with the end effector, thereby securing the part to the end effector.

[0005] The part transfer system may further include multiple sensors, each coupled to one of a plurality of partitions. Each of the multiple sensors is configured to sense whether the pressure in each of the multiple partitions is equal to or less than a predetermined pressure threshold, and an end effector is configured to be fixed to the part when the pressure in at least one of the multiple partitions is equal to or less than the predetermined pressure threshold. At least one of the multiple sensors may be a flow sensor. At least one of the multiple sensors may be a passive pressure sensor.

[0006] This disclosure also describes a method for transferring a part (e.g., a longitudinal beam). In one aspect of this disclosure, the method includes: (a) activating a vacuum source, wherein the vacuum source is in fluid communication with a plurality of sections of an end effector, the end effector including a plurality of vacuum ports, each vacuum port being in fluid communication with at least one of the plurality of sections; (b) moving the end effector toward the part until the end effector engages with the part; (c) after the end effector engages with the part, keeping the end effector stationary until the pressure in at least one of the plurality of sections is equal to or less than a predetermined pressure threshold; and (d) moving the end effector and the part together toward a mating tray until the part is placed on the mating tray.

[0007] The method may further include sensing the pressure in each of the plurality of partitions using multiple sensors. Each of the plurality of sensors may be configured to sense whether the pressure in each of the plurality of partitions is equal to or less than a predetermined pressure threshold. An end effector may be configured to be fixed to a part when the pressure in at least one of the plurality of partitions is equal to or less than the predetermined pressure threshold. The method may further include separating at least one of the plurality of partitions from the remainder of the plurality of partitions. The method may further include blocking fluid flow between a vacuum source and at least one of the plurality of vacuum ports.

[0008] The vacuum source may be referred to as the first vacuum source as discussed above. The method may further include fluidly disconnecting the vacuum source from multiple vacuum ports of the end effector after the part has been placed on the mating tray. The mating tray may include a tray body and multiple vacuum tray ports extending through the tray body. Each of the multiple vacuum tray ports may be in fluid communication with a second vacuum source to draw gas from the multiple vacuum tray ports to secure the part to the mating tray when it is arranged on the mating tray.

[0009] The method may further include fluidly connecting a second vacuum source to a plurality of vacuum tray ports to evacuate gas from the plurality of vacuum tray ports to secure the part to the mating tray after the part has been arranged on the mating tray. The method may further include commanding the second vacuum source to activate via a controller to evacuate gas from the plurality of vacuum tray ports. The method may further include using an indexing mechanism to align the part with the mating tray while moving an end effector toward the mating tray along with the part.

[0010] The foregoing features and advantages, as well as other features and advantages, of this teaching will become apparent when viewed in conjunction with the accompanying drawings and in the following detailed description of the model used to carry out this teaching. Attached Figure Description

[0011] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of this disclosure and, together with the description, serve to explain the principles of this disclosure.

[0012] Figure 1 This is a schematic perspective view of a parts transfer system, depicting the pick-up and placement system.

[0013] Figure 2 yes Figure 1 A schematic perspective view of the pick-and-place system.

[0014] Figure 3 yes Figure 1 A schematic diagram of the pick-up and placement system.

[0015] Figure 4 yes Figure 1 A schematic bottom view of the pick-up and place system.

[0016] Figure 5 yes Figure 1 A schematic front view of the sensors in the pickup and placement system.

[0017] Figure 6 yes Figure 1 A schematic perspective view of the tray that accompanies the parts transfer system.

[0018] Figure 7 It revolves around Figure 6 A schematic enlarged perspective view of a portion of the matching tray, taken from area A.

[0019] Figure 8 This is a schematic diagram of a portion of an indexing mechanism used to align a pick-and-place system with a forming device, wherein the forming device includes a forming device cup.

[0020] Figure 9 This is a schematic diagram of a portion of an indexing mechanism for aligning a pick-and-place system with another pick-and-place system, wherein the pick-and-place system includes pins.

[0021] Figure 10 This is a schematic diagram of a portion of an indexing mechanism used to align a pick-and-place system with a matching tray, wherein the matching tray includes a tray cup.

[0022] Figure 11 It is a schematic perspective cross-sectional view of the indexing mechanism, which includes the pins of the pick-up and place system placed in the tray cup of the matching tray.

[0023] Figure 12 This is a flowchart of the method for transferring parts.

[0024] Figure 13 yes Figure 1 A schematic perspective view of a part transfer system, in which an end effector engages with a part.

[0025] Figure 14 yes Figure 1A schematic perspective view of a part transfer system in which parts are lifted from a forming machine.

[0026] Figure 15 yes Figure 1 A schematic perspective view of a parts transfer system, in which parts are moving toward a matching tray.

[0027] Figure 16 yes Figure 1 A schematic perspective view of a parts transfer system, in which parts will be placed on matching trays. Detailed Implementation

[0028] The foregoing summary of the invention and the following detailed description of certain embodiments will be better understood when read in conjunction with the accompanying drawings. As used herein, an element or step referred to in the singular and preceded by the word "a (an)" should be understood to not necessarily exclude multiple elements or steps. Furthermore, the reference to "one embodiment" is not intended to be construed as excluding the existence of additional embodiments that also incorporate the described features. Moreover, unless expressly stated to the contrary, an embodiment "comprising" or "having" one or more elements with a particular property may include additional elements that do not have that property.

[0029] refer to Figure 1 and Figure 2 This disclosure describes a parts transfer system 100 for transferring a part 102 (e.g., a longitudinal beam) from a forming unit 104 to a mating tray 106. As used herein, the term "longitudinal beam" refers to a longitudinal structural member in an aircraft frame. During assembly, part 102 is secured to the aircraft skin for structural support. Part 102 may be made wholly or partially of a metallic or polymeric material, such as a polymer composite. Regardless of the material used, part 102 may have different dimensions (e.g., length).

[0030] During manufacturing, it may be necessary to move parts 102 of different sizes from the forming unit 104 to the mating tray 106. Therefore, it is desirable to use the same parts transfer system 100 to move parts 102 of different sizes from one location to another. By using the currently disclosed parts transfer system 100, the manufacturing operator does not need to use a different transfer system to move parts 102 of different sizes. Instead, the manufacturing operator can simply use the currently disclosed parts transfer system 100 to move parts 102 of different sizes from the forming unit 104 to the mating tray 106, thereby saving time and reducing costs.

[0031] The parts transfer system 100 includes a pick-and-place system 108 configured to pick up part 102 and then move part 102 from one location to another. The pick-and-place system 108 includes a movable support 110. Figure 2 ) and multiple arms 112 connected to the movable support 110 Figure 2 The movable support 110 can be arranged horizontally and can be moved by a lifting frame or another suitable device. As a non-limiting example, the movable support 110 can be configured as a positioning plate or beam specifically designed to rigidly support a plurality of arms 112. Each of the plurality of arms 112 is coupled to the movable support 110. Therefore, the arms 112 can move simultaneously with the movable support 110. Each of the arms 112 can move independently of the movable support 110 and has three free axes. Two axes are pivots 119a and 119b, and one axis is a stroke (i.e., linear motion). Therefore, each arm 112 can move linearly as indicated by the double arrow DA.

[0032] refer to Figure 1-4 The pick-and-place system 108 further includes an end effector 114 configured to pick up and hold part 102. The end effector 114 can be configured as a compactor to conform to the cavity of part material 102a (e.g., beam material) formed on the forming element 104. Regardless of its specific configuration, the end effector 114 is attached to the arm 112. Because the arm 112 is coupled to the movable support 110, the end effector 114 can move as the movable support 110 moves.

[0033] The end effector 114 includes a body 116 and a plurality of partitions 118, each partition 118 being coupled to the body 116. The partitions 118 divide the body 116 into a plurality of sections 120. Therefore, fluid cannot flow between the sections 120. In other words, the sections 120 are fluidly separated from each other. For this purpose, each of the sections 120 may be referred to as an hermetically sealed section 120. The partitions 118 may be configured, for example, to be inserted into a cutout in the body 116 of the end effector 114 as a metal or polymer component. In the depicted embodiment, the body 116 of the end effector 114 includes four sections 120: a first section 120a, a second section 120b, a third section 120c, and a fourth section 120d. However, it is contemplated that the body 116 of the end effector 114 may be divided into more or fewer sections 120. One or more sections 120 may be detachably coupled to each other to accommodate parts 102 of different sizes. This is primarily due to the consideration of having a modular system that can be manufactured in short batches (at a lower cost) and then assembled according to the length of the forming machine. Furthermore, this allows for the replacement of defective modules in the event of damage. Therefore, for example, if we have two part lines of different lengths, one 60 feet and the other 30 feet, then we would use six 10' modules on the longer line and three 10' modules on the second line. This allows the first line to build any part up to 60' in length, and the second line to build any part up to 30' in length, while the end actuator modules on both lines use the same parts. For example, the first section 120a and the second section 120b can be detachably connected to each other. The second section 120b and the third section 120c can be detachably connected to each other, and the third section 120c and the fourth section 120d can be detachably connected to each other. By detachably connecting the sections 120 to each other, the pick-and-place system 108 can accommodate parts 102 of different sizes.

[0034] The end effector 114 further includes a plurality of vacuum ports 122. Each vacuum port 122 is in fluid communication with at least one of the partitions 120. The vacuum ports 122 may be directly attached to the body 116 of the end effector 114. Each vacuum port 122 may be configured to be fluidly coupled to an orifice of one or more partitions 120. The parts transfer system 100 further includes a first vacuum source 124 in fluid communication with the plurality of partitions 120 via the vacuum ports 122, thereby allowing fluid to flow from the partitions 120 to the first vacuum source 124 via the vacuum ports 122. When the first vacuum source 124 is activated, each vacuum port 122 is configured to draw fluid F(F) from the plurality of partitions 120. Figure 5Vacuum ports, such as air, are used to create a vacuum between the end effector 114 and the part 102 that engages with the end effector 114 to secure the part 102 to the end effector 114. The end effector 114 has a maximum length ML, and at least two vacuum ports 122 are spaced apart from each other along the maximum length ML of the end effector 114 to accommodate parts 102 of different sizes.

[0035] refer to Figure 1-5 The pick-and-place system 108 further includes a plurality of sensors 126, each sensor 126 being coupled to one or more partitions 120. Each sensor 126 is configured to sense whether the pressure in one of the plurality of partitions 120 is less than a predetermined pressure threshold. When the pressure in one or more partitions 120 is equal to or less than the predetermined pressure threshold, the end effector 114 is secured to the part 102. In other words, when the pressure in one or more partitions 120 is equal to or less than the predetermined pressure threshold, a vacuum created between the end effector 114 and the part 102 causes the end effector 114 to firmly hold the part 102. As discussed above, the sensors 126 detect when the pressure in each partition 120 reaches or is less than the predetermined pressure threshold. As a non-limiting example, one or more sensors 126 may be configured as passive pressure sensors or flow sensors. For example, one or more of the sensors 126 may be configured as a check valve 128 ( Figure 5 The first vacuum source 124 is configured to selectively draw fluid F from one or more of the sections 120 of the end effector 114. This allows fluid to flow only in one direction SD, but prevents it from flowing in the opposite direction. However, when the pressure in one or more sections 120 is equal to or less than a predetermined pressure threshold, the check valve 128 prevents fluid F from flowing in the one-way direction SD and its opposite direction, indicating that the pressure in one or more sections is equal to or less than the predetermined pressure threshold. Therefore, the first vacuum source 124 is configured to selectively draw fluid F from one or more sections 120 of the end effector 114. Figure 5 The control system 130 (i.e., the controller) communicates with the first vacuum source 124, and therefore, the control system 130 can control the operation of the first vacuum source 124. For example, the control system 130 can be programmed to command the first vacuum source 124 to fluidly disconnect from the vacuum port 122 of the end effector 114 when the vacuum tray port 111 of the mating tray 106 is in fluid communication with the second vacuum source 138.

[0036] The vacuum port 122 of sensor 126 and end effector 114 is in fluid communication with a first vacuum source 124. The first vacuum source 124 may be configured as a vacuum pump or another device to remove gas molecules from a sealed volume to leave a complete or partial vacuum. In this disclosure, each section 120 of the body 116 of end effector 114 defines a gas-sealed volume. When the first vacuum source 124 is activated, gas molecules are removed from the section 120 (which is gas-sealed) to leave a complete or partial vacuum in the section 120, thereby allowing end effector 114 to securely hold part 102. Once the pressure in the section 120 of end effector 114 is equal to or less than a predetermined pressure threshold, movable support 110 can be moved to move end effector 114 (which securely holds part 102) to mating tray 106.

[0037] The parts transfer system 100 may further include a control system 130 that electronically communicates with the mating tray 106, the pick-and-place system 108, and the first vacuum source 124. Therefore, the control system 130 is configured to receive input data 131 from the mating tray 106, the pick-and-place system 108, and the first vacuum source 124, and to provide output data 133 to the mating tray 106, the pick-and-place system 108, and the first vacuum source 124. The control system 130 may also be referred to as a controller and may include hardware elements such as a processor 132, circuitry including, but not limited to, timers, oscillators, analog-to-digital (A / D) circuitry, digital-to-analog (D / A) circuitry, digital signal processors, and input / output (I / O) devices, as well as other signal conditioning and / or buffering circuitry. In addition to the processor 132, the control system 130 may include a memory 134 that communicates with the processor 132. Memory 134 may include tangible, non-transitory memory, such as read-only memory (ROM), for example, magnetic, solid-state / flash memory and / or optical memory, and a sufficient number of random access memories (RAM), electrically erasable programmable read-only memories (EEPROM), etc. Control system 130 may additionally include a user interface 136 that communicates with processor 132. User interface 136 may include a keyboard, display, touchscreen, or other input or output device that allows users to input data and the processor to output data. In addition to user interface 136, control system 130 may be other hardware or software used to control part transfer system 100.

[0038] The control system 130 can also electronically communicate with a second vacuum source 138 in fluid communication with the mating tray 106. The second vacuum source 138 can be a vacuum pump or another device that removes gas molecules from a sealed volume to leave a complete or partial vacuum in the mating tray 106, as discussed below. While the depicted embodiment shows a first vacuum source 124 for the pick-and-place system 108 and a second vacuum source 138 for the mating tray 106, it is conceivable that the parts transfer system 100 may include more or fewer vacuum sources. For example, the parts transfer system 100 may include a single vacuum source for both the pick-and-place system 108 and the mating tray 106.

[0039] refer to Figure 1 , 6 As discussed above, the pick-and-place system 108 is configured to move part 102 from the forming unit 104 to the mating tray 106. The mating tray 106 is configured to receive part 102. The mating tray 106 includes a tray body 109 and a recess 113 defined in the tray body 109, which is configured, shaped, and sized to receive part 102. The mating tray 106 may be straight, for general longitudinal beams, or a net shape including unique or semi-unique longitudinal beams. The recess 113 may extend along the entire length of the tray body 109. Regardless of its specific shape, the mating tray 106 has a plurality of vacuum tray ports 111 extending through the tray body 109. It is conceivable that the mating tray 106 may include a raised portion / platform instead of the recess 113. The raised portion may act as a convex tool surface to mate with the concave part 102. In this case, the end effector 114 may be a concave tool to pick up part 102 formed on the convex tool. The part 102 can then be moved to the convex tool tray. Each of the vacuum tray ports 111 is in fluid communication with the second vacuum source 138. In other words, the mating tray 106 is in fluid communication with the second vacuum source 138 via the vacuum tray ports 111. The vacuum tray ports 111 are arranged along the length of the tray body 109 on opposite sides of the recess 113 to securely hold the part 102 when it is placed in the recess 113 and the second vacuum source 138 is activated. The mating tray 106 may include the vacuum tray ports 111 in the longitudinal beam flange area to ensure that the flange is free from natural loosening and tending to lift. Flatness helps the scanner verify the shape and dimensions of the manufactured longitudinal beam. For other configurations of the tray with the convex feature, the vacuum feature may be positioned in the cross section as needed to aid manufacturing. The second vacuum source 138 is configured to draw gas (e.g., air) from the vacuum tray ports 111 when the part 102 is placed on the mating tray 106 to secure the part 102 to the mating tray 106.

[0040] The mating tray 106 includes multiple sections 115 that can be separated from each other. The mating tray 106 includes multiple partition walls 121 to separate the sections 115, thereby preventing fluid flow between the sections 115. Due to the sections 115 and the partition walls 121, the mating tray 106 can accommodate parts 102 independently of its size when the second vacuum source 138 is activated. The vacuum chambers created by the sections 115 can be appropriately sized to accommodate any incremental differences in part length that require a solution. The sections 115 are also detachably connected to each other. Therefore, one or more sections 115 of the mating tray 106 can be separated from other sections 115 to accommodate parts 102 of different sizes. For example, the mating tray 106 could be 10 feet long with multiple 5-foot sections 115. Alternatively, we could have a 10-foot tray using 5-foot modules to accommodate short longitudinal beams, then 20 feet and 30 feet, and so on, simply adding up the lengths of the longitudinal beams. Furthermore, the mating tray 106 can be 20 feet or 30 feet long. Alternatively, the mating tray 106 can be a 40-foot tray for all parts 102, regardless of part length. The mating tray 106 may include end plugs 117 to hermetically seal the end section 115e of the section 115. Fluid separation occurs at the vacuum tray port 111, but does not necessarily continue throughout. The mating tray 106 can have fluid continuity between sections 115 to distribute process vacuum (shop vacuum) to the vacuum tray port 111. Due to weight, the mating tray 106 itself may not be a vacuum chamber, but rather a hose may be used to move a small amount of air. The mating tray 106 does not function as an accumulator and therefore does not degrade the sensor's responsiveness.

[0041] refer to Figure 8-11The parts transfer system 100 further includes an indexing mechanism 140 configured to align the pick-and-place system 108 with the former 104 and / or the mating tray 106. The indexing mechanism 140 may be a cup-and-cone system, and in this case, the pick-and-place system 108 may include a pin 142. Optionally, the indexing mechanism 140 may be optical, hard-stop, GPS, or another type of indexing mechanism. The former 104 may include a former cup 144 (or cone) shaped and sized to receive the pin 142 of the pick-and-place system 108 to align the pick-and-place system 108 with the former 104. The mating tray 106 may include a tray cup 146 (or cone) configured to receive the pin 142 to align the pick-and-place system 108 with the mating tray 106. To align the mating tray 106 with the pick-and-place system 108, the pin 142 is placed inside the tray cup 146 of the mating tray 106. Therefore, pin 142 is shaped and sized to be arranged within tray cup 146 to align mating tray 106 with pick-and-place system 108, and is shaped and sized to be arranged within molder cup 144 to align pick-and-place system 108 with molder 104.

[0042] refer to Figure 12-16 Method 200 can be performed to transfer part 102 from one location to another, such as from forming device 104 to mating tray 106. Method 200 begins at block 202, where part 102 or longitudinal beam material 102a is provided. Part 102 can be of general length or can be trimmed to a desired length. Method 200 then proceeds to block 204.

[0043] At box 204, part 102 is placed in a predetermined position, such as in... Figure 13 On the shown forming device 104. In other words, part 102 is staged in an off-center position, such as on forming device 104. At box 204, one or more partitions 120 can be separated from the remaining partitions 120 to accommodate the length of part 102. Optionally, part 102 is supported by fully covered partitions 120. Due to sensor 126, the partially covered partitions 102 at the ends do not engage, and the rigidity of part 102 is sufficient to keep part 102 straight. Method 200 then proceeds to box 206. At box 206, end effector 114 is provided. As discussed above, end effector 114 can be used as a compactor to shape part 102. After box 206, method 200 continues to box 210.

[0044] At box 210, end effector 114 moves toward part 102 until end effector 114 engages part 102. For example, end effector 114 may move toward part 102 until end effector 114 is in direct contact with part 102. While moving end effector 114 toward part 102, end effector 114 may be aligned with formor 104 by inserting pin 142 into formor cup 144 of indexing mechanism 140 (or by using other suitable indexing mechanism). End effector 114 may apply pressure to part 102 disposed on formor 104 to change the shape of part 102, thereby allowing part 102 to be assembled onto a particular aircraft. Alternatively, formor 104 may produce part 102 (e.g., a longitudinal beam) and end effector 114 may only retrieve part 102. When end effector 114 engages part 102, partition 120 of end effector 114 is covered by part 102. In method 200, a first vacuum source 124 is also provided at block 211. At this stage of the process, at block 210, after engaging part 102 with end effector 114, the first vacuum source 124 is activated. Thus, at block 211, the first vacuum source 124 is activated. As discussed above, the first vacuum source 124 is in fluid communication with partition 120 of end effector 114 via vacuum port 122. Method 200 then continues to block 212.

[0045] At block 212, the partition 120 of the end effector 114, covered by part 102, accumulates vacuum pressure due to a small flow rate through sensor 126. This vacuum pressure accumulates until the vacuum pressure at each partition 120 is equal to or less than a predetermined pressure threshold. For this purpose, the first vacuum source 124 should be turned on until the vacuum pressure at each partition 120 is equal to or less than the predetermined pressure threshold, and the end effector 114 should remain stationary until the vacuum pressure at each partition 120 is equal to or less than the predetermined pressure threshold. At block 212, sensor 126 senses whether the pressure in each partition 120 is equal to or less than the predetermined pressure threshold. When the pressure in each partition 120 is equal to or less than the predetermined pressure threshold, part 102 is secured to end effector 114. Sensor 126 may be a check valve that allows fluid F to flow from part 102 to the first vacuum source 124 when the vacuum pressure in the partition 120 is greater than the predetermined pressure threshold, but prevents fluid flow F between part 102 and the end effector when the vacuum pressure in the partition is equal to or less than the predetermined pressure threshold. In other words, at block 212, once the vacuum pressure in partition 120 is equal to or less than a predetermined pressure threshold, fluid flow between the first vacuum source 124 and the vacuum port 122 can be blocked. In response to a determination by, for example, sensor 126, that the pressure in each partition 120 is equal to or less than the predetermined pressure threshold, method 200 proceeds to block 214.

[0046] At box 214, the control system 130 can command the pickup and placement system 108 to automatically lift the end effector 114 and the fixed part 102 in response to determining that the pressure in each partition 120 is equal to or less than a predetermined pressure threshold. Figure 14 As shown in the diagram. At this stage, part 102 is secured to end effector 114. Therefore, lifting end effector 114 causes part 102 to be lifted as well. Optionally, control system 130 may generate an alarm (e.g., a visual or audible alarm) to notify the user of part transfer system 100 that end effector 114 is secured to part 102 and can therefore be moved to another location, such as mating tray 106. The user can then command pick and place system 108 to move to another location via user interface 136 of control system 130. Method 200 then proceeds to blocks 216 and 218.

[0047] At box 216, a mating tray 106 is provided. Method 200 then proceeds to box 220. At box 220, part 102 (which is fixed to end effector 114) moves toward mating tray 106 until part 102 is placed on mating tray 106, as... Figure 15 and 16 As shown. To align the end effector 114 with the mating tray 106, the pin 142 of the pick-and-place system 108 can be inserted into the tray cup 146 of the indexing mechanism 140 while moving the part 102. Alternatively, other suitable indexing mechanisms can be used to align the end effector 114 with the mating tray 106. Method 200 then proceeds to block 221.

[0048] At box 220, after part 102 is placed on mating tray 104, at box 221, a second vacuum source 138 can be opened to draw gas (e.g., air) from the vacuum tray port 111 of mating tray 106, thereby securing part 102 to mating tray 106. At box 221, in response to, for example, determining that fluid F is no longer being drawn by the vacuum port 122 of end effector 114, control system 130 can command the second vacuum source to start (i.e., open). Thus, at this stage, the second vacuum source 138 is fluidly connected to the vacuum tray port 111 of mating tray 106. Once part 102 is arranged on mating tray 106, end effector 114 should remain connected to (e.g., in direct contact with) part 102 at the interface where the vacuum pressure between mating tray 106 and part 102 is equal to or less than a predetermined pressure threshold, so as to secure part 102 to mating tray 106 before disconnecting end effector 114 from part 102. The mating tray 106 may include a sensor, such as the sensor 126 described above, to measure the vacuum pressure at the interface between the mating tray 106 and the part 102. In response to determining that the vacuum pressure at the interface between the mating tray 106 and the part 102 is equal to or less than a predetermined pressure threshold, method 200 proceeds to block 222.

[0049] At block 222, the first vacuum source 124 can be shut off. As a result, part 102 is released from end effector 114. At block 222, the first vacuum source 124 can be fluidly disconnected from the vacuum port 122 of end effector 114. Once part 102 is released from end effector 114, method 200 continues to block 224. At block 224, end effector 114 is removed from part 102.

[0050] As used herein, a system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any changes, and not merely has the potential to perform the specified function after further modifications. In other words, a system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the specified function. As used herein, “configured to” means that the existing features of the system, apparatus, structure, article, element, component, or hardware enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modifications. For the purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as “configured to” perform a particular function may additionally or alternatively be described as “adapted to” and / or described as being “operated to” perform that function.

[0051] Clause 1. According to one aspect of this disclosure, a part transfer system is provided, comprising a movable support; a plurality of arms coupled to the movable support; an end effector coupled to each of the plurality of arms, the end effector including a body and a plurality of partitions, each partition coupled to the body, the plurality of partitions dividing the body into a plurality of partitions, and the end effector including a plurality of vacuum ports, each vacuum port being in fluid communication with one of the plurality of partitions; and a vacuum source in fluid communication with at least one of the plurality of vacuum ports, wherein each of the plurality of vacuum ports is configured to draw fluid from the even-numbered plurality of partitions to establish a vacuum between the end effector and a part engaged with the end effector, thereby securing the part to the end effector.

[0052] Clause 2. The part transfer system according to Clause 1 further includes a plurality of sensors, each sensor being coupled to one of the plurality of partitions, wherein each of the plurality of sensors is configured to sense whether the pressure in each of the plurality of partitions is equal to or less than a predetermined pressure threshold, and an end effector is configured to be fixed to the part when the pressure in at least one of the plurality of partitions is equal to or less than the predetermined pressure threshold.

[0053] Clause 3. The parts transfer system according to Clause 2, wherein at least one of the plurality of sensors is a flow sensor.

[0054] Clause 4. The parts transfer system according to Clause 2, wherein at least one of the plurality of sensors is a passive pressure sensor.

[0055] Clause 5. The parts transfer system according to Clause 1, wherein the plurality of partitions includes at least a first partition and a second partition, and the first partition and the second partition are detachably connected to each other.

[0056] Clause 6. The parts transfer system according to Clause 1, wherein the vacuum source is configured to selectively draw fluid from at least one of the plurality of partitions.

[0057] Clause 7. The parts transfer system according to Clause 1 further includes a mating tray configured to receive the parts, wherein the movable support is configured to move to place the parts on the mating tray.

[0058] Clause 8. The parts transfer system according to Clause 7, wherein the vacuum source is a first vacuum source, and the parts transfer system further includes a second vacuum source in fluid communication with the mating tray, the mating tray including a tray body and a plurality of vacuum tray ports extending through the tray body, and each of the plurality of vacuum tray ports being in fluid communication with the second vacuum source to draw gas from the plurality of vacuum tray ports to secure the parts to the mating tray when the parts are placed on the mating tray.

[0059] Clause 9. The parts transfer system according to Clause 8 further includes an indexing mechanism configured to align the end effector with the forming device and the mating tray.

[0060] Clause 10. The parts transfer system according to Clause 9, wherein the indexing mechanism is a cup / cone system.

[0061] Clause 11. The parts transfer system according to Clause 8 further includes a controller in communication with the first vacuum source, wherein the controller is programmed to command the first vacuum source to fluidly disconnect from the plurality of vacuum ports of the end effector when the plurality of vacuum tray ports are in fluid communication with the second vacuum source.

[0062] Clause 12. The part transfer system according to Clause 1, wherein the end effector has a maximum length, and at least two of the plurality of vacuum ports are spaced apart from each other along the maximum length of the end effector.

[0063] Clause 13. According to another aspect of this disclosure, a method for transferring a part is provided, comprising activating a vacuum source, wherein the vacuum source is in fluid communication with a plurality of partitions of an end effector, the end effector including a plurality of vacuum ports, each vacuum port being in fluid communication with at least one of the plurality of partitions; moving the end effector toward the part until the end effector engages with the part; after the end effector engages with the part, keeping the end effector stationary until the pressure in at least one of the plurality of partitions is equal to or less than a predetermined pressure threshold; and moving the end effector together with the part toward a mating tray until the part is placed on the mating tray.

[0064] Clause 14. The method according to Clause 13, further comprising using a plurality of sensors to sense pressure in each of the plurality of partitions, wherein each of the plurality of sensors is configured to sense whether the pressure in each of the plurality of partitions is equal to or less than the predetermined pressure threshold, and the end effector is configured to be fixed to the part when the pressure in at least one of the plurality of partitions is equal to or less than the predetermined pressure threshold.

[0065] Clause 15. The method according to Clause 13 further includes separating at least one of the plurality of partitions from the remainder of the plurality of partitions.

[0066] Clause 16. The method according to Clause 13 further includes blocking fluid flow between the vacuum source and at least one of the plurality of vacuum ports.

[0067] Clause 17. The method according to Clause 13, wherein the vacuum source is a first vacuum source, and the method further includes fluidly disconnecting the vacuum source from the plurality of vacuum ports of the end effector after placing a part on the mating tray, wherein the mating tray includes a tray body and a plurality of vacuum tray ports extending through the tray body, and each of the plurality of vacuum tray ports is in fluid communication with a second vacuum source to draw gas from the plurality of vacuum tray ports to secure the part to the mating tray when the part is placed on the mating tray.

[0068] Clause 18. The method according to Clause 17 further comprises fluidly connecting the second vacuum source to the plurality of vacuum tray ports to draw gas from the plurality of vacuum tray ports to secure the part to the mating tray after the part has been placed on the assembly tray.

[0069] Clause 19. The method according to Clause 18 further includes commanding the second vacuum source to start via a controller to draw gas from the plurality of vacuum tray ports.

[0070] Clause 20. The method according to Clause 13 further includes using an indexing mechanism to align the part with the mating tray while moving the end effector together with the part toward the mating tray.

[0071] The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. The illustrations are not intended to be a complete description of all elements and features of an apparatus and system utilizing the structures or methods described herein. Many other embodiments may become apparent to those skilled in the art upon reading this disclosure. Other embodiments can be utilized and derived from this disclosure, allowing structural and logical substitutions and changes to be made without departing from the scope of this disclosure. Therefore, this disclosure and the accompanying drawings are to be considered illustrative rather than restrictive.

Claims

1. A parts transfer system, comprising: Movable support components; Multiple arms; An end effector coupled to each of the plurality of arms, the end effector comprising a body and a plurality of partitions, each partition being coupled to the body, the plurality of partitions dividing the body into a plurality of partitions, and the end effector comprising a plurality of vacuum ports, each vacuum port being in fluid communication with one of the plurality of partitions; and A vacuum source in fluid communication with at least one of the plurality of vacuum ports, each of the plurality of vacuum ports being configured to draw fluid from the plurality of partitions to establish a vacuum between the end effector and a part engaging with the end effector, thereby securing the part to the end effector; wherein: The plurality of partitions includes at least a first partition and a second partition, and the first partition and the second partition are detachably connected to each other; and / or the vacuum source is configured to selectively draw fluid from at least one of the plurality of partitions; and Each of the plurality of arms is coupled to the movable support such that the arm can move simultaneously with the movable support, wherein each of the arms is capable of moving independently of the movable support and has three free axes, two of which are pivots and one of which is a stroke for linear motion.

2. The part transfer system of claim 1, further comprising a plurality of sensors, each sensor coupled to one of the plurality of partitions, wherein each of the plurality of sensors is configured to sense whether the pressure in each of the plurality of partitions is equal to or less than a predetermined pressure threshold, and the end effector is configured to be fixed to the part when the pressure in at least one of the plurality of partitions is equal to or less than the predetermined pressure threshold.

3. The parts transfer system according to claim 2, wherein at least one of the plurality of sensors is a flow sensor.

4. The parts transfer system according to claim 2, wherein at least one of the plurality of sensors is a passive pressure sensor.

5. The part transfer system according to any of the preceding claims, wherein the end effector has a maximum length ML, and at least two of the plurality of vacuum ports are spaced apart from each other along the maximum length ML of the end effector.

6. The parts transfer system of claim 1, further comprising a matching tray configured to receive the parts, wherein the movable support is configured to move to place the parts on the matching tray.

7. The parts transfer system of claim 6, wherein the vacuum source is a first vacuum source, and the parts transfer system further includes a second vacuum source in fluid communication with the mating tray, the mating tray including a tray body and a plurality of vacuum tray ports extending through the tray body, and each of the plurality of vacuum tray ports being in fluid communication with the second vacuum source to draw gas from the plurality of vacuum tray ports to secure the parts to the mating tray when the parts are placed on the mating tray.

8. The parts transfer system of claim 7, further comprising an indexing mechanism configured to align the end effector with the forming device and the mating tray.

9. The parts transfer system according to claim 8, wherein the indexing mechanism is a cup / cone system.

10. The parts transfer system of claim 7, 8 or 9, further comprising a controller in communication with the first vacuum source, wherein the controller is programmed to command the first vacuum source to fluidly disconnect from the plurality of vacuum ports of the end effector when the plurality of vacuum tray ports are in fluid communication with the second vacuum source.

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