Fixing device and method of using it

Abstract

A fixing device is provided comprising a robot arm having a plurality of rotation axes, one or more position cameras, a controller communicating with the robot arm to control the displacement and joints of the robot arm using at least partially position data received from the one or more position cameras, a mirror gripper positioned at a first end of the robot arm to engage with a mirror, and an air knife having one or more nozzles for providing an air sheet of forced air.

Description

Technology Field

[0001] (Cross-reference to related applications)

[0002] This application claims priority to U.S. provisional patent application no. 63 / 011,434 filed on April 17, 2020, the disclosure of which is incorporated herein in its entirety for all purposes.

[0003] (Technology field)

[0004] The fixture and its method of use relate to the field of automated component fixtures. Background Technology

[0005] Automotive exterior rearview mirrors are used to provide the driver with a view of objects behind and to the sides of the vehicle. These mirrors typically consist of a glass substrate with a reflective coating. To address issues related to cold weather, such as ice or snow adhering to the mirror, manufacturers may mount electric heater elements on the back of the mirror. These heater elements are available in various known forms, one of which is a single trace of aluminum wrapped across a substrate (e.g., polyester), where heat is generated from the resistance of the trace when electricity is applied. Another type of heater element is known as a PTC (Positive Temperature Coefficient) heater.

[0006] Heater elements are typically fixed to a glass substrate during the manufacturing process. Due to the unique characteristics of the heater elements, mounting them to the glass substrate is problematic and labor-intensive. Attempts to automate the mounting process are also difficult. The problem to be solved

[0007] One solution to such problems involves the use of fixtures. A fixture is a device used in the manufacturing industry to maintain or support operations. Fixtures are generally used to support operations and ensure that all parts produced using the fixture maintain fit and compatibility, thereby allowing for the safe placement of the work (positioned in a specific location or orientation). To date, fixtures have not been successfully used to mount heater elements, as they have been used in attempts to create air bubbles that must be removed by manual squeegee operation. Furthermore, in the case of convex mirrors, manufacturing such fixtures is complex and costly. Due to various problems, including those mentioned above, manually securing heater elements to glass substrates has been the standard practice, despite the need for additional manual squeegees and the inconsistent fixation and limited results. means of solving the problem

[0008] In at least some embodiments, a fixing device is provided comprising: a robot arm having a plurality of rotation axes; one or more position cameras; a controller communicating with the robot arm to control the displacement and joints of the robot arm using at least partially position data received from the one or more position cameras; a mirror gripper positioned at a first end of the robot arm to engage with a mirror; and an air knife having one or more nozzles for providing an air sheet of forced air.

[0009] In at least some other embodiments, a method for fixing a heater element to a mirror comprises: providing a robot arm having a plurality of rotation axes, one or more position cameras, a controller communicating with the robot arm to control the displacement and joints of the robot arm using at least partially position data received from the one or more position cameras, and a mirror gripper located at a first end of the robot arm; then, jointly connecting the robot arm to a first position using the mirror gripper on a mirror having a mirror front and a mirror rear; applying a vacuum force to fix the mirror front to the mirror gripper; jointly connecting the robot arm from the first position to the mirror located adjacent to a heater element having a heater front and a heater rear; further jointly connecting the robot arm until the mirror rear is at least partially engaged with the heater front so that the heater element moves coincidentally with the mirror; and providing an air sheet of forced air. A method for fixing a heater element to a mirror is provided, comprising the step of jointly connecting the robot arm to the mirror and the heater element so that the robot arm passes through the air sheet to apply a forced airflow along the rear of the heater to laminate the front of the heater to the rear of the mirror.

[0010] In at least some other embodiments, a fixing device is provided comprising: a robot arm having a plurality of rotation axes; one or more position cameras; a controller communicating with the robot arm to control the displacement and joints of the robot arm using at least partially position data received from the one or more position cameras; a mirror gripper positioned at a first end of the robot arm to engage with a mirror; and a heater-applied fixing device having one or more suction ports that provide a vacuum force flow of air.

[0011] In at least another embodiment, a method for fixing a heater element to a mirror comprises: providing a first robot arm and a second robot arm each having a plurality of rotation axes, one or more position cameras, a controller communicating with the first robot arm and the second robot arm to control displacement and joints using at least partially position data received from the one or more position cameras, and a mirror gripper located at a first end of the robot arm; jointly connecting the first robot arm to a first position using the mirror gripper on a mirror having a mirror front and a mirror rear; applying a vacuum force to fix the mirror front to the mirror gripper; jointly connecting the first robot arm to a second position; coupling a heater element having a heater front and a heater rear to the second robot arm; jointly connecting the second robot arm until the heater front is at least partially engaged with the mirror rear so that the heater element moves simultaneously with the mirror; and providing an air sheet of forced air. A method for fixing a heater element to a mirror is provided, comprising the step of jointly connecting the first robot arm to gradually pass through the mirror and the heater element through the air sheet to apply a forced airflow along the rear of the heater to laminate the front of the heater to the rear of the mirror.

[0012] Other embodiments, aspects, and features of the fixing device and method of use will be understood by fully reading the detailed description and the following claims. Brief explanation of the drawing

[0013] Exemplary embodiments of the fixing device and method of use are disclosed with reference to the accompanying drawings and are for illustrative purposes only. The fixing device and method of use are not limited to the details of the configuration or arrangement of the components shown in the drawings in the application. Other embodiments of the fixing device and method of use are possible, or may be practiced or performed in various other ways. FIG. 1 is a perspective view of an exemplary fixture. FIG. 2 is a perspective view of the fixture of FIG. 1 having a mirror and a heater element together. Fig. 3 is a front view of an exemplary mirror of Fig. 2. FIG. 4 is a rear view of an exemplary mirror of FIG. 2. Fig. 5 is a rear view of an exemplary heater element of Fig. 2. Fig. 6 is a front view of an exemplary heater element of Fig. 2. Figure 7 is an exemplary flowchart providing steps for a method of fixing a heater element to a mirror. Fig. 8 is a partial side view of the fixture, mirror, and heater element of Fig. 2. FIG. 9 is a second exemplary embodiment of an air knife. FIG. 10 is an exemplary heater application fixture. FIG. 11 is a perspective view of an exemplary second robot arm. Specific details for implementing the invention

[0014] Referring to FIG. 1, an exemplary fixing device (100) is illustrated. In at least some embodiments, the fixing device (100) comprises a robot arm (102) having a plurality of pivoting joints (103) to provide a plurality of rotation axes (e.g., six axes) to allow three-dimensional movement in various ways. In at least some embodiments, when the robot arm (102) is fixed to a gripping mechanism, the robot arm (102) obtains the function of picking up and moving an object based on a user-defined path / command. The robot arm (102) comprises a base end (104) that can be fixed to fix the robot arm (102), and a grip end (106) that may include various components for gripping and manipulating an object. In at least some embodiments, the grip end (106) includes a mirror gripper (108) configured to engage with a mirror (122) (see FIG. 2), and the grip end (106) and the mirror gripper (108) include a central axis (111) extending therethrough. The mirror gripper (108) may utilize any of various types of coupling methods, such as a vacuum, to grasp an object. In at least some embodiments, the mirror gripper (108) is a vacuum-operated gripper comprising an easily adaptable foam portion having a portion in contact with a bottom surface (109) (Fig. 8), and the mirror gripper (108) passes through the bottom surface (109) and, in some embodiments, may have an array of orifices (not shown) that may include check valves to allow a vacuum to be maintained even when the component being handled is smaller than the gripper. Through these features, the gripper can handle various shapes, sizes, and contours of glass. In at least some embodiments, the bottom surface (109) of the mirror gripper (108) is generally flat, but in other embodiments, the bottom surface (109) may be curved to match the contour of the object being picked up.In at least some embodiments, the grip end (106) may further include a cover gripper (110) for gripping and peeling off a protective cover sheet (not shown) from an adhesive surface on the back of an object such as a blind spot detection display module and a heater element. The cover gripper (110) may utilize any various type of coupling method, such as opposing fingers (112) that are closed on a portion of the cover sheet.

[0015] Referring additionally to FIG. 1, at least one position camera (114) may be included in the fixture (100) or otherwise utilized by it. The position camera (114) is positioned to view the robot arm (102) as well as other components to provide position data of all relevant components. Since it is well known that position cameras are used to track the movement and position of components, it should be understood that any wiring and software used to provide tracking information is included as needed. In at least some embodiments, the position camera (114) is a known machine vision camera capable of positioning components randomly oriented in a plane based on their X, Y, and R (rotation) coordinates and providing information as position data when combined with known machine vision software (e.g., iRVision manufactured by Fanuc American Corp. in Rochester Hills, Michigan, USA). The camera-acquired position data is provided to a controller (116) to operate the robot arm (102) accordingly. The position camera (114) can be mounted in various ways, such as a camera arm (115) positioned adjacent to the robot arm (102).

[0016] The fixed device (100) further includes a controller (116) that communicates with the position camera (114) and the robot arm (102) and controls the displacement and joints of the robot arm (102) using at least partially position data received from the position camera and / or associated software. The controller (116) may be composed of various types of known components commonly used for robot motor control, such as a Programmable Logic Controller (PLC) and associated known control software (e.g., RSLogix 5000). The controller (116) accesses program commands to move the robot arm (102) as discussed below. The use of PLCs and control software to position and manipulate the robot arm is well known, and therefore specific program commands to perform any desired movement are not described in detail herein.

[0017] By using program commands along with camera position data, the controller (116) can effectively move the item as desired. Still referring to FIG. 1, the fixture (100) further includes an air knife (118) comprising one or more air nozzles (120) that provide airflow. Air knives are generally well known and can provide various different airflow outputs, such as the Model 110024 air knife manufactured by Exair, for example. In at least some embodiments, one or more air nozzles (120) are shaped and sized to provide a substantially linear sheet (i.e., air sheet (177)) of upward forceful air generated from the output of the air nozzles (120) (see FIG. 8 and 9). The air sheet (177) provides an upward force of air (air force). Moving an object along a linear path orthogonal to the air sheet (177) (e.g., arrow (172) in FIG. 8) creates a squeegee-like effect that has the same length as the flow pattern on the surface of the object.

[0018] Referring to FIG. 2, a fixing device (100) is illustrated with a mirror (122) and an electric heater element (124). The mirror (122) may include various types of substrates used in external vehicle rearview mirrors, such as glass coated to provide reflection. As illustrated in FIG. 3 and FIG. 4, the mirror (122) includes a mirror front (126) and a mirror rear (128). As illustrated in FIG. 5 and FIG. 6, the heater element (124) includes a heater front (130) and a heater rear (132), and is sized and shaped to be fixed to the mirror rear (128). In at least some embodiments, the heater front (130) includes an adhesive layer thereon for fixation to the mirror rear (128), whereas in other embodiments, the mirror rear (128) may include an adhesive layer.

[0019] Referring to FIG. 7, a flowchart (140) is provided that illustrates exemplary steps for a method of securing a heater element (124) to a mirror (122). As illustrated, in step (150), the controller (116) articulates the robot arm (102) to position the mirror gripper (108) over the mirror front with the grip end (106) and the center axis (111) of the mirror gripper (108) in a vertical position, and lowers the mirror gripper (108) to engage with the mirror front (126). In step (152), the mirror gripper (108) temporarily secures the mirror (122) to it by applying a vacuum force to the mirror (122). In step (154), the controller (116) joints the robot arm (102) to lift the mirror (122) and move the mirror gripper (108) from a first position where the mirror rear (128) is located directly above the heater front (130). In step (156), the mirror gripper (108) moves downward until the mirror rear (128) engages at least partially with the heater front (130). As further described below, in at least some embodiments, instead of moving the mirror (122) to the heater element (124) for adhesion, the heater element (124) may be moved to the mirror (122) on the mirror gripper (108) by a separate heater robot arm, where the heater robot arm engages the heater front (130) with the mirror rear (128) while the mirror is held in place. In step (158), the mirror gripper (108) is raised and the mirror (122) and heater element (124) are moved to the starting position above and in front of the air knife (118) (see FIG. 8).In step (160), while the air nozzle (120) blows forced air pressure upward (identified by arrow (170) in FIG. 8) against the rear of the heater (132) to form an air sheet (177), the robot arm (102) moves the mirror (122) and the heater element (124) over the air nozzle (120) of the air knife (118). In at least some embodiments, the direction of movement (identified by arrow (172) in FIG. 8) is perpendicular or substantially perpendicular to the air sheet (177) provided by the air nozzle (120) extending in the longitudinal direction, and the center axis (111) of the grip end (106) and the mirror gripper (108) is parallel to the upward air pressure (i.e., arrow (170)). In this way, when the mirror (122) is passed over the air knife (118) and the air sheet (177), the released air pressure forces the heater element (124) against the mirror back (128) to uniformly laminate the components together. Since vehicle mirrors such as the mirror (122) generally have a convex shape, attaching the flat and flexible heater element (124) to the mirror back (128) is easily achieved by the force of the air sheet (177) that adapts to the convex shape. In at least some embodiments, the air knife (118) may be moved instead while the mirror gripper (108) remains stationary.

[0020] Referring to FIG. 9, another exemplary embodiment of an air knife, the air knife (119) is shown to use multiple air nozzles (121) rather than a single long, narrow nozzle, and the air nozzles (121) are shaped and positioned to provide an upward air force that is similar to the overall longitudinally linear force illustrated by the arrow (174) to create an air sheet (177).

[0021] Referring to FIG. 10, in at least some embodiments, the fixture (100) may include a heater application fixture (180) instead of an air knife (118). The heater application fixture (180) provides a plurality of suction ports (i.e., suction cups) (184) that provide a vacuum force (shown by arrow (186)) to maintain and form a surface (182) having a contour similar to the contour of the mirror rear surface (128) and a heater element (124) on the surface (182). A vacuum line (187) is coupled to the suction ports (184) to provide a switchable vacuum source. With the heater application fixture (180), instead of progressively passing the mirror (122) and the heater element (124) over the air nozzle, the robot arm (102) lowers the mirror (122) over the heater element (124) already placed on the surface (182) where its adhesive is exposed. As the robot arm (102) pushes the mirror (122) down against the heater element (124) to laminate the components together, the vacuum in the suction port (184) forcibly pulls or holds the heater element (124) to the surface (182).

[0022] As mentioned above, in at least some embodiments, the fixing device (100) may include a second robot arm (200) having a plurality of pivoting joints (203) that provide a plurality of rotational axes to allow three-dimensional movement in various ways. The second robot arm (200) is similar to the robot arm (102) and includes a gripping mechanism capable of picking up and delivering an object based on a user-defined path / command. The second robot arm (200) may include a base end (204) that can be fixed to fix the second robot arm (200), and a grip end (206) that may include various components for gripping and manipulating an object. In at least some embodiments, the grip end (206) includes a heater element gripper (210) configured to engage with a heater element (124). The second robot arm (200) may be used to pick up the heater element (124) and position it to engage with the mirror (122). In particular, rather than the robot arm (102) being articulated so that the heater element (124) and the mirror (122) placed on the horizontal plane are engaged, the heater element (124) may be picked up and articulated by a second robot arm (200) to engage with the mirror (122) which is held in place by the robot arm (102). In this way, the steps (154 and 156) described above will be replaced by: the step of articulated the robot arm (102) to a second position; the step of attaching the heater element (124), having a heater front (130) and a heater rear (132), to the second robot arm (200); and the step of articulated the second robot arm (200) until the heater front (130) engages at least partially with the mirror rear (128) so that the heater element (124) moves coincidentally with the mirror.

[0023] Fixing devices and methods of use are not limited to the embodiments and examples included herein, but are specifically intended to include modified forms of such embodiments, including combinations of parts of embodiments and elements of different embodiments within the scope of the claims below. Additionally, the steps described herein in relation to the method of use (process) should not be construed as limiting and may include variations such as additional steps, removed steps, and rearranged steps. Specific materials, shapes, and sizes of components may vary. Use of the term “plural” in the description or claims should be understood to include “one or more.”

[0024] While the present invention is particularly useful in automotive mirror assemblies, other applications are possible, and references to its use in mirror assemblies should not be construed as limiting the application of the invention. Rather, the invention may be advantageously applied to uses requiring similar performance capabilities and characteristics, and such modifications may be made by those skilled in the art without departing from the spirit or intent of the invention; therefore, the invention is deemed to include all reasonable equivalents to the subject matter.

Claims

Claim 1 A fixing device characterized by comprising: a first robot arm having a plurality of rotational axes; one or more position cameras; a programmable logic controller communicating with the first robot arm to control the displacement and joints of the first robot arm using at least partially position data received from the one or more position cameras; a mirror gripper positioned at a first end of the first robot arm to engage with a mirror—the mirror gripper is a vacuum-actuated gripper having a foam portion having an array of vacuum orifices that directly contact the upper surface of the mirror—; an air knife having one or more nozzles for outputting a forceful air sheet; and a second robot arm having a plurality of rotational axes—the programmable logic controller communicating with the second robot arm to control the displacement and joints of the second robot arm, and the second robot arm positioning a heater element for engagement with the mirror engaged with the mirror gripper of the first robot arm. Claim 2 delete Claim 3 delete Claim 4 A fixing device according to claim 1, further comprising a cover gripper extending from the first robot arm. Claim 5 A fixing device according to claim 4, wherein the cover gripper is characterized by compromising the opposing closable fingers. Claim 6 A fixing device according to claim 1, wherein the one or more nozzles of the air knife are positioned to provide a substantially linear airflow in which the air sheet is substantially oriented vertically. Claim 7 A fixing device according to claim 1, characterized in that at least one of the one or more position cameras is fixed and positioned adjacent to the first robot arm. Claim 8 A fixing device according to claim 1, wherein the one or more nozzles of the air knife are positioned such that the air sheet extends perpendicularly and parallelly to the central axis of the mirror gripper. Claim 9 A fixing device according to claim 8, wherein the first robot arm comprises at least six rotation axes. Claim 10 A fixing device according to claim 9, wherein the first robot arm comprises at least two vertical rotation axes and four horizontal rotation axes. Claim 11 delete Claim 12 delete Claim 13 A method for fixing a heater element to a mirror, comprising: a robot arm having a plurality of rotation axes; one or more position cameras; a controller communicating with the robot arm to control the displacement and joints of the robot arm using at least partially position data received from the one or more position cameras; and a mirror gripper located at a first end of the robot arm; a step of articulating the robot arm to a first position using the mirror gripper on a mirror having a mirror front and a mirror rear; a step of applying a vacuum force to fix the mirror front to the mirror gripper; a step of articulating the robot arm from the first position using the mirror located adjacent to a heater element having a heater front and a heater rear; a step of further articulating the robot arm until the mirror rear is at least partially engaged with the heater front so that the heater element moves coincidentally with the mirror; and a step of providing an air sheet of forced air. A method for fixing a heater element to a mirror, characterized by including the step of jointly connecting the robot arm to pass through the mirror and the heater element gradually through the air sheet to apply a forced airflow along the rear surface of the heater in order to laminate the front surface of the heater to the rear surface of the mirror. Claim 14 A method for fixing a heater element to a mirror, wherein, in paragraph 13, the robot arm moves substantially perpendicularly to the air seat while passing through the mirror and the heater element. Claim 15 A method for fixing a heater element to a mirror, wherein, in paragraph 14, the air sheet is provided by one or more nozzles of an air knife positioned so that the air sheet extends vertically. Claim 16 delete Claim 17 delete Claim 18 delete Claim 19 delete Claim 20 A method for fixing a heater element to a mirror, comprising: a first robot arm and a second robot arm each having a plurality of rotation axes; one or more position cameras; a controller communicating with the first robot arm and the second robot arm to control displacement and joints using at least partially position data received from the one or more position cameras; and a mirror gripper located at a first end of the robot arm; a step of jointly connecting the first robot arm to a first position using the mirror gripper on a mirror having a mirror front and a mirror rear; a step of applying a vacuum force to fix the mirror front to the mirror gripper; a step of jointly connecting the first robot arm to a second position; a step of coupling a heater element having a heater front and a heater rear to the second robot arm; a step of jointly connecting the second robot arm until the heater front is at least partially engaged with the mirror rear so that the heater element moves coincidentally with the mirror; and a step of providing a powerful air sheet. A method for fixing a heater element to a mirror, characterized by including the step of jointly connecting the first robot arm to gradually pass through the mirror and the heater element through the air sheet to apply a forced airflow along the rear surface of the heater in order to laminate the front surface of the heater to the rear surface of the mirror.

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