System and method for automated assembly of components

Abstract

A system (12) for automatically manipulating components (38) to be assembled onto a product (14) on an assembly line (16) includes a carriage (34) movable to a first retracted position spaced from the assembly line (16) and a second position displaced from the retracted position in a direction toward the assembly line (16) and movable between the first retracted position and the second position. An operator (32) on the carriage (34) supports a component mounting tool (36) configured to receive and support at least one component (38) for assembly to the product (14). The operator (32) is arrangeable in a first orientation when the carriage (34) is in the first position and pivotable to a second orientation when the carriage (34) is in the second position so that the component (38) on the component mounting tool (36) is supported in a pose for handling when the carriage (34) is in the first position and the component is supported in a pose for joining to the product (14) when the carriage (34) is in the second position.

Description

Technical Field

[0001] The present invention relates generally to automated manufacturing systems and, more particularly, to systems and methods for the automated assembly of components. Background Art

[0002] Automation plays an increasingly important role in the manufacturing and assembly of products. As manufacturing systems become increasingly automated, there is a corresponding increase in the use of robotic manipulators for manufacturing, handling, and assembling components and sub-components into final products. One example of such an automated manufacturing system can be found in the automotive industry, where automated manufacturing lines assemble complete vehicles from component parts. Many automated manufacturing systems utilize assembly lines with multi-axis robotic manipulators working in a coordinated manner to handle and assemble components into the desired final product. Typically, these multi-axis robotic manipulators include multiple links arranged in series that are moved by motors to perform handling and assembly functions.

[0003] As these manufacturing systems have become more automated, the tolerances between assembled components have become increasingly smaller. While conventional six-degree-of-freedom manipulators provide the flexibility required for these highly automated manufacturing systems, the configuration of robotic manipulators with serially arranged linkages can result in looser tolerances in assembled components or require frequent calibration of the robotic manipulators to ensure that tight tolerances can be achieved and maintained. Therefore, a need exists for improved automated systems that facilitate the rapid, efficient, and repeatable assembly of components into final products and that overcome these and other shortcomings of current automated manufacturing systems. Summary of the Invention

[0004] The present invention provides a system and related methods for automating the assembly of components onto workpieces on an assembly line. Although the present invention will be described in conjunction with certain embodiments, it will be understood that the invention is not limited to these embodiments. Rather, the present invention encompasses all alternatives, modifications, and equivalents within the spirit and scope of the present disclosure.

[0005] In one aspect, an exemplary system for automatically manipulating components to be assembled to a product on an assembly line includes a carriage supported on a frame that positions the system near the assembly line. The carriage is movable to a first retracted position spaced a distance from the assembly line and a second working position displaced from the retracted position in a direction toward the assembly line and movable between the first retracted position and the second working position. The carriage supports a multi-axis articulated manipulator, which in turn supports a component installation tool configured to receive and support at least one component for assembly to the product. When the carriage is in the first position, the manipulator can be arranged in a first orientation, and when the carriage is in the second position, the manipulator can be pivoted to a second orientation such that when the carriage is in the first position, the component on the component installation tool is supported in a posture for handling, and when the carriage is in the second position, the component is supported in a posture for attachment to the product.

[0006] In another aspect, a method for manipulating a component to be assembled to a product on an assembly line includes receiving the component on a component installation tool at a first retracted position spaced from the assembly line, and moving the component installation tool toward the assembly line to a second working position. In the first position, the component installation tool is in a first posture suitable for facilitating receiving or handling the component. In the second position, the component installation tool is in a second posture suitable for facilitating attaching the component to the product.

[0007] The following exemplary embodiments identify various aspects of automated systems and related methods for assembling components according to the principles of the present disclosure.

[0008] Example 1. A system for automatically manipulating components to be assembled into products on an assembly line, the system comprising:

[0009] a frame that can be located near the assembly line;

[0010] a carriage supported on the frame, the carriage being adapted to move to a first retracted position spaced a distance from the assembly line and a second working position displaced from the retracted position in a direction toward the assembly line, and between the first retracted position and the second working position; a multi-axis articulated manipulator supported on the carriage, the manipulator comprising a base coupled to the carriage, and a tool mounting plate controllably movable relative to the base in at least three degrees of freedom;

[0011] The operator base is arranged in a first orientation when the carriage is in the first position, and the operator base is pivoted to a second orientation when the carriage is in the second position; and

[0012] a component installation tool coupled to the tool mounting plate of the operator, the component installation tool being configured to receive and support at least one component for assembly to the product;

[0013] Wherein when the carriage is in the first position, the component on the component mounting tool is supported in a posture for loading and / or handling, and when the carriage is in the second position, the component is supported in a posture for attachment to a product.

[0014] Example Embodiment 2. The system of Example Embodiment 1 wherein the component mounting tool is variably configurable to support different components having different geometries.

[0015] Example Embodiment 3. The system of any of Example Embodiments 1-2, wherein the component installation tool comprises:

[0016] a tool frame connectable to a tool mounting plate of the operator;

[0017] at least one shaft assembly supported on the tool frame;

[0018] Each shaft assembly includes:

[0019] at least one trunnion,

[0020] a shaft supported on at least one trunnion,

[0021] At least one gripping member is mounted on the shaft and actuatable to supportably engage the component.

[0022] Example Embodiment 4. The system of Example Embodiment 3 wherein the at least one shaft assembly includes a first shaft assembly and a second shaft assembly supported on the tool frame.

[0023] Example Embodiment 5. The system of any of Example Embodiments 3-4, wherein:

[0024] Each shaft assembly includes a plurality of gripping members positioned at different circumferential locations about the shaft;

[0025] wherein gripping members positioned at different circumferential locations about the shaft are configured to engage components having different geometries; and each shaft is rotatable relative to the tool frame about the shaft's longitudinal axis, whereby selected gripping members are positioned to engage the component by rotation of the corresponding shaft.

[0026] Exemplary Embodiment 6. The system of any of Exemplary Embodiments 3-5, wherein the at least one gripping member comprises a plurality of gripping members, the gripping members being configured as air actuators adapted to sealingly engage the component when vacuum pressure is supplied to the air actuators.

[0027] Example Embodiment 7. The system of Example Embodiment 6, wherein:

[0028] Each shaft assembly includes a plurality of air manipulators positioned at different circumferential locations about the shaft;

[0029] wherein the air manipulators at different circumferential locations about the shaft are configured to engage components having different geometries; and each shaft is rotatable relative to the tool frame about the shaft's longitudinal axis whereby selected air manipulators are positioned to engage the component by rotation of the corresponding shaft.

[0030] Example Embodiment 8. The system of one of Example Embodiments 5 or 7, further comprising:

[0031] A locking assembly is on the tool frame and is operable to lock the shaft against rotation relative to the tool frame.

[0032] Example 9. The system of any of Example 6-8, further comprising:

[0033] At least one passageway passes through the shaft and is configured to provide selective communication between a source of vacuum pressure and at least one air actuator, whereby vacuum pressure is provided to the air actuator when the air actuator is positioned to engage the component.

[0034] Example Embodiment 10. The system of any of Example Embodiments 1-9, wherein the operator comprises:

[0035] at least three linkage mechanisms coupled between the operator base and the tool mounting plate;

[0036] Each linkage has a first end pivotally coupled to the tool mounting plate;

[0037] Each linkage has a second end opposite the first end and coupled to the operator base for controllable movement along at least one translation axis in a plane parallel to the base.

[0038] Example Embodiment 11. The system of Example Embodiment 10 wherein at least three linkages have a fixed longitudinal length.

[0039] Example Embodiment 12. The system of Example Embodiment 10 further comprising:

[0040] At least one actuator is disposed between the second end of each respective linkage and the base.

[0041] Example Embodiment 13. The system of Example Embodiment 12 wherein the at least one actuator comprises a first actuator and a second actuator disposed between the second end of each respective linkage and the base.

[0042] Example Embodiment 14. The system of Example Embodiment 13 wherein the first actuator associated with each linkage is a linear actuator arranged to control movement of the respective second end in a first direction, and the second actuator is a linear actuator arranged to control movement of the respective second end in a second direction orthogonal to the first direction.

[0043] Example Embodiment 15. A method of manipulating a component to be assembled to a product on an assembly line, the method comprising: receiving the component on a component installation tool at a first retracted position spaced from the assembly line, wherein the component installation tool is in a first posture adapted to facilitate receiving or handling the component;

[0044] The component on the component installation tool is moved in a direction toward the assembly line to a second working position in which the component installation tool is in a second posture suitable for facilitating attachment of the component to the product.

[0045] Example Embodiment 16. The method of Example Embodiment 15, wherein:

[0046] The component installation tool is supported on a multi-axis manipulator having a manipulator base; and

[0047] Moving the component on the component installation tool to the second working position includes moving the operator base from a first posture at the first position to a second posture having a different orientation at the second position.

[0048] Exemplary Embodiment 17. The method of any of Exemplary Embodiments 15-16, wherein:

[0049] The component installation tool includes at least one air operator configured to sealingly engage the component using vacuum pressure; and

[0050] The method further includes selectively providing vacuum pressure to at least one air operator.

[0051] Example Embodiment 18. The method of Example Embodiment 17, wherein:

[0052] The at least one air manipulator comprises a plurality of air manipulators configured to sealingly engage components having different geometries; and

[0053] The method further includes selectively indexing at least one of the plurality of air manipulators into a position and orientation for sealingly engaging the component.

[0054] Example 19. The method of Example 18 further comprising:

[0055] Cooperating with the indexing to selectively provide vacuum pressure to the at least one air operator.

[0056] Exemplary Embodiment 20. The method of any of Exemplary Embodiments 15-19, further comprising at least one of the following:

[0057] adding a sub-component to the component while the component is supported on the component installation tool at a first position; or

[0058] A manufacturing process is performed on the component while the component is supported on the component installation tool in a first position.

[0059] The above and other objects and advantages of the present invention will become apparent from the accompanying drawings and description thereof. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the present invention and, together with the general description of the present invention given above and the detailed description given below, serve to explain the principles of the present invention.

[0061] Figure 1 is a schematic plan view of an illustrative manufacturing plant including a system for manipulating components according to the principles of the present disclosure.

[0062] Figure 2 is a perspective view of an illustrative system for manipulating a component according to the principles of the present disclosure.

[0063] Figure 3A yes Figure 2 A partial elevational view of a system illustrating the carriage supported in a first, retracted position.

[0064] Figure 3B is similar to Figure 3A Also illustrated is a partial elevational view of the carriage in a second position.

[0065] Figure 4 According to the principles of this disclosure Figure 2 Detail perspective view of an exemplary multi-axis articulated manipulator in a system.

[0066] Figure 5 According to the principles of this disclosure Figure 2 Detail perspective view of an exemplary component installation tool in a system.

[0067] Figure 6 It was intercepted along line 6-6 Figure 5 Cross-sectional view of a component installation tool. DETAILED DESCRIPTION

[0068] Figure 1An exemplary manufacturing facility 10 according to the principles of the present disclosure is depicted, which includes an exemplary system 12 for automatically handling components to be assembled onto a workpiece 14 moving along a manufacturing assembly line 16. In the illustrated embodiment, the manufacturing facility 10 includes a plurality of independent manufacturing cells 18a, 18b, 18c, 18d positioned adjacent to and on either side of the manufacturing assembly line 16. The assembly line 16 may include a conveyor structure (not shown) for automatically moving the workpiece 14 along the assembly line 16 (such as in the direction of arrow 20), whereby the workpiece 14 may be positioned adjacent to the plurality of manufacturing cells 18a-18d, and automated systems, such as robotic manipulators, may assemble components onto or process the workpiece 14 as part of the manufacturing process. In the illustrated embodiment, the workpiece 14 is depicted as a motor vehicle, and the cells 18a-18d of the manufacturing facility 10 are configured to assemble components onto the vehicle body or perform various processing steps that may be desired. Although the exemplary embodiment is shown and described herein as a manufacturing facility 10 having cells 18a - 18d adapted for assembling and processing vehicles, it will be appreciated that the manufacturing facility 10 and cells 18a - 18d may alternatively be configured to produce various other products.

[0069] Continue to refer Figure 1 , an exemplary manufacturing cell 18a may include an exemplary component handling system 12 according to the principles of the present disclosure. The component handling system 12 may be arranged in the cell 18a near a plurality of robotic manipulators. For example, a first robotic manipulator 22a may be configured to pick up one or more components from a supply source (not shown) and position the components on or within the component handling system 12. The first robotic manipulator 22a may be located within the manufacturing cell 18a, or alternatively, may be placed near the manufacturing cell 18a and may be configured to extend within the manufacturing cell 18a in cooperation with the component handling system 12. Additional robotic manipulators 22b, 22c may be positioned within the cell 18a and may be configured to cooperate with the component handling system 12 to facilitate assembly and / or processing of components positioned by the component handling system 12 for assembly onto the workpiece 14. Although the exemplary manufacturing cell 18a has been shown and described herein as including several robotic manipulators 22a, 22b, 22c cooperating with the component handling system 12, it will be appreciated that various other configurations of manufacturing cells may alternatively be used.

[0070] Continue to refer Figure 1 , and further reference Figure 2 、 3A3B, depicts in greater detail an exemplary component handling system 12 according to the principles of the present disclosure. In the illustrated embodiment, the component handling system 12 may be supported on a frame 30 for positioning within the manufacturing cell 18a and adjacent the manufacturing line 16. The exemplary component handling system 12 includes a multi-axis articulated manipulator 32 supported on the frame 30 by a carriage 34. The carriage 34 is supported on the frame 30 for movement to a first retracted position spaced a distance from the assembly line (e.g., Figure 3A ) and a second working position (as depicted in FIG) displaced from the retracted position in a direction toward the assembly line 16. Figure 3B ) and moves between a first retracted position and a second, operative position. In the illustrated embodiment, the carriage 34 is selectively moved between the first and second positions by an actuator 26 having an extendable rod 28. However, it will be appreciated that various other mechanisms suitable for moving the carriage 34 between the first and second positions may be used.

[0071] The exemplary component handling system 12 further includes a component installation tool 36 that is coupled to the multi-axis manipulator 32 and is configured to receive and support at least one component 38 for assembly to the workpiece 14. In the illustrated embodiment, the component 38 is illustrated as a door that is to be installed to the vehicle body as the vehicle body moves along the assembly line 16 and is positioned adjacent the manufacturing cell 18a. Although the component 38 is shown and described herein as a vehicle door, it will be appreciated that in other embodiments, various other components may be received on the component installation tool 36 for handling and / or assembly to the workpiece. As non-limiting examples, automotive components (such as body panels, handles, or hinges) or even non-automotive components may be received and supported on the component installation tool in accordance with the principles of the present disclosure.

[0072] like Figure 3A As shown in , when the carriage 34 is in the first retracted position, the installation tool 36 is oriented and positioned to receive the component 38 and to support the component 38 in a posture to facilitate further processing of the component 38, such as by a robotic manipulator 22a positioned adjacent the component handling system 12. As a non-limiting example of the embodiment shown, the component 38 in the form of a vehicle door may be supported with the interior side of the door facing upward to thereby facilitate positioning and attachment of sub-components to the door. Advantageously, the first position of the carriage 34 facilitates loading and processing of components and sub-components while the workpiece 14 is moved between the manufacturing cells 18a-18d of the manufacturing assembly line 16, thereby providing an increase in throughput efficiency. When the carriage 34 is then moved to the position as shown in , the installation tool 36 is oriented and positioned to receive the component 38 and to support the component 38 in a posture to facilitate further processing of the component 38, such as by a robotic manipulator 22a positioned adjacent the component handling system 12. As a non-limiting example of the embodiment shown, the component 38 in the form of a vehicle door may be supported with the interior side of the door facing upward to thereby facilitate positioning and attachment of sub-components to the door. Advantageously, the first position of the carriage 34 facilitates loading and processing of components and sub-components while the workpiece 14 is moved between the manufacturing cells 18a-18d of the manufacturing assembly line 16, thereby providing an increase in throughput efficiency. Figure 3BIn the second work position depicted in FIG. 3B, the installation tool 36 is translated with the carriage 34 and is also moved in a curvilinear manner so that the installation tool 36 supports the member 38 in a second attitude for facilitating joining of the member 38 to the workpiece 14. For example, in the illustrated embodiment, the member 38 can be supported in a generally vertical orientation corresponding to how the door attaches to the body of the vehicle (workpiece 14).

[0073] The member handling system 12 can also be provided with various sensors for monitoring and facilitating operation of the member handling system 12. In the illustrated embodiment, the system 12 can further include one or more optical sensors or cameras 40 positioned at various suitable locations on or near the operator 32, carriage 34, and / or member installation tool 36. For example, the optical sensors 40 can be supported on a separate support frame 42, or can be coupled with the frame 30 or other structure as can be desired. As non-limiting examples, other sensors can include one or more non-contact proximity sensors 44 positioned on or near the member handling system 12 and configured to sense the presence of the workpiece 14 near the member handling system 12. Other sensors can be used to confirm the presence and / or attitude of a member supported on the member installation tool 36. Signals or data obtained from the sensors 40, 44 can be provided to a controller or other suitable computer and used to control and / or monitor operation of the member handling system 12.

[0074] With continuing reference to Figure 2 , 3A and 3B, and further reference to Figure 4, an exemplary multi-axis articulated manipulator 32 will be described in greater detail. In the illustrated embodiment, the manipulator 32 includes a base assembly 50 that couples the manipulator 32 to the carriage 34 for movement with the carriage 34 between a first position and a second position on the frame 30. A plurality of linkages 52 are coupled to a base plate 54 of the base assembly 50 and are configured to support a tool mounting plate 56 at opposite ends thereof for coupling with the component mounting tool 36. In the illustrated embodiment, the manipulator 32 includes three fixed-length linkages 52 coupled to the base plate 54 at first ends 58 thereof, and second ends 60 of the linkages 52 are coupled to the tool mounting plate 56. The first ends 58 of the linkages 58 are coupled to the base plate 54 by respective pivot joints 62 and at least one actuator configured to controllably move the second ends 60 of the linkages 52. The coordinated movement of the second ends 60 of the linkages 52 allows the posture (position and orientation) of the tool mounting plate 56 to be precisely controlled. In the illustrated embodiment, the first end 58 of each linkage 52 is coupled to the base plate 54 by a pair of linear actuators 66a, 66b arranged to control movement of the first end 58 of the linkage 52 in respective first and second directions 68, 70, disposed orthogonally to one another. The second end 60 of the linkage 52 is coupled to the tool mounting plate 56 by respective swivel joints 72, such that the posture of the tool mounting plate 56 can be controlled by selective positioning of the linear actuators 66a, 66b coupled to the respective linkage 52. In use, the multi-axis manipulator 32 facilitates precise positioning of a component 38 supported by a component mounting tool 36 coupled to the tool mounting plate 56 when the carriage 34 is in the second position.

[0075] When the carriage 34 is in the Figure 3A When in the first position shown in FIG, the base plate 54 of the multi-axis manipulator 32 is oriented so that the component installation tool 36 coupled to the tool mounting plate 56 is in the above-described posture for receiving and supporting the component 38. Figure 2 and 3B As shown in FIG, as the carriage moves from the first position to the second position, the base plate 54 pivots to an orientation that causes the component mounting tool 36 coupled to the tool mounting plate 56 to move to the above-described position for joining the component 38 to the workpiece 14.

[0076] Although the multi-axis manipulator 32 has been shown and described herein as including three fixed-length linkages 52 and linear actuators 66a, 66b coupling the linkages 52 to the manipulator base plate 54, it will be appreciated that various other linkage and actuator arrangements, including variable-length linkages, may alternatively be used to facilitate positioning the tool mounting plate 56 in a desired posture for mounting the component 38 to the workpiece 14.

[0077] Continue to refer Figure 2 、 3A and 3B, and further references Figure 5 and 6 , an exemplary component installation tool 36 according to the principles of the present disclosure will be described. In the illustrated embodiment, the component installation tool 36 includes a tool frame 80 configured to couple with the tool mounting plate 56 of the multi-axis manipulator 32. One or more shaft assemblies 82a, 82b are supported on the tool frame 80 and, in turn, support gripping members 84 that are configured to engage and support the component 38 to be mounted to the workpiece 14. In the illustrated embodiment, the installation tool 36 includes a first shaft assembly 82a and a second shaft assembly 82b supported on the tool frame 80. Each shaft assembly 82a, 82b includes a shaft 86a, 86b that is supported by a corresponding trunnion mount 88 for rotation relative to the tool frame 80. Each shaft 86a, 86b may further include a plurality of gripping members 84 positioned at spaced circumferential positions about the shaft 86. Advantageously, each gripping member 84 may be configured to engage components having different geometries, whereby certain of the gripping members 84 may be selectively positioned to engage components 38 to be assembled to the workpiece 14 by rotating the shaft 86 about its respective longitudinal axis 90a, 90b relative to the frame 80.

[0078] like Figure 6 As best seen in FIG, the component installation tool 36 may further include a locking assembly 92 that cooperates with one or more of the shaft assemblies 82a, 82b to lock the shafts 86a, 86b in a desired rotational position so that the selected gripping member 84 can be positioned to engage the component 38. In the illustrated embodiment, the locking assembly 92 includes an actuator 94 having an extendable rod 96 that engages the associated shaft assembly 82a, 82b to thereby lock the corresponding shaft 86a, 86b in the desired rotational position. To this end, each shaft assembly 82a, 82b further includes a registration block 98 that is supported on the shaft 86a, 86b and has a registration feature configured to cooperate with the rod 96 of the locking assembly actuator 94. In the illustrated embodiment, the distal end 100 of the rod 96 has a wedge-shaped tip, and the registration feature on the registration block includes a correspondingly shaped notch 102 disposed at a selected angular position about the shaft 86a, 86b. In use, when the desired gripping member 84 is in position for engagement with component 38, the rod 96 of the locking assembly actuator 94 may extend to engage a corresponding notch 102 provided on the registration block 98, thereby preventing further rotation of the shafts 86a, 86b.

[0079] Although the component installation tool 36 has been shown and described herein as including two shaft assemblies 82a, 82b, each having a plurality of gripping members 84 disposed at spaced circumferential locations, it will be appreciated that a component installation tool according to the present disclosure may alternatively include only a single shaft assembly, or may include more than two shaft assemblies. Furthermore, when only a single type of component is to be manipulated by the component installation tool 36, or when the components have a sufficiently uniform geometry, the component installation tool 36 may not require a plurality of different gripping members 84 disposed circumferentially around the shaft assemblies 82a, 82b.

[0080] In the illustrated embodiment, the gripping member 84 of the component installation tool 36 is configured as an air actuator adapted to sealingly engage the component when vacuum pressure is supplied to the air actuator. Figure 6 As best shown in FIG, each air manipulator includes a housing 110 supported on a corresponding shaft 86a, 86b by a bracket assembly 112. The air manipulator is configured such that one or more sealing members 116 are configured to sealingly engage a suction surface 114 of the component 38, and a vacuum opening 118 formed in the housing 110 communicates with the suction surface 114 to provide a vacuum pressure sufficient to engage and support the component 38. The vacuum opening 118 of each air manipulator can be coupled to a vacuum pressure source (not shown) that can be controlled to selectively grasp and release the component 38.

[0081] In the illustrated embodiment, each shaft 86a, 86b includes at least one air passage 120a, 120b, 120c, 120d extending through the shaft 86a, 86b and configured to provide selective communication between a vacuum pressure source and a corresponding vacuum opening 118 of the air actuator, such as, for example, via a corresponding hose (not shown). In one embodiment, one or more of the air passages 120a, 120b, 120c, 120d extending through the shafts 86a, 86b of the shaft assemblies 82a, 82b can be configured to provide selective communication between the vacuum pressure source and a selected air actuator when the corresponding shaft 86a, 86b is rotated to a position that positions the air actuator to engage the component 38, while the other air passages 120a, 120b, 120c, 120d extending through the shafts 86a, 86b are not in communication with the vacuum pressure source, thereby providing no vacuum pressure to air actuators not engaged with the component 38. In the illustrated embodiment, the component installation tool 36 further includes a slip ring associated with each shaft assembly 82a, 82b to provide electrical and / or vacuum pressure to the air passages 120a, 120b, 120c, 120d through the shafts 86a, 86b. An exemplary slip ring that can be used is the Pneumatic Rotary Union, part number 3004012, available from Senruipu Electronics Co., Ltd. in Guangdong, China.

[0082] While the application has been illustrated by a description of various embodiments, and while these embodiments have been described in considerable detail, it is not the intention that the application be limited to or by the details of the above-discussed embodiments. Various modifications can be made without departing from the spirit and scope of the application. Accordingly, the various features and aspects of the application can be used individually or in any combination. Additional advantages and modifications will readily appear to those skilled in the art. The application in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures can be made from such details without departure from the spirit or scope of the general inventive concept.

Claims

1. A system for automatically manipulating components to be assembled into products on an assembly line, the system comprising: a frame capable of being located adjacent to said assembly line; a carriage supported on the frame, the carriage being adapted to move to a first retracted position spaced a distance from the assembly line and a second working position displaced from the first retracted position in a direction toward the assembly line, and between the first retracted position and the second working position; a multi-axis articulated manipulator supported on the carriage, the manipulator comprising a manipulator base coupled to the carriage, and a tool mounting plate controllably movable relative to the manipulator base in at least three degrees of freedom; the operator base being arranged in a first orientation when the carriage is in the first retracted position and pivoting to a second orientation when the carriage is in the second operating position; as well as a component installation tool coupled to the tool mounting plate of the operator, the component installation tool being configured to receive and support at least one component for assembly to the product; wherein when the carriage is in the first retracted position, the component on the component mounting tool is supported in a posture for loading and / or handling, and when the carriage is in the second working position, the component is supported in a posture for attachment to the product.

2. The system according to claim 1, wherein: The component mounting tool can be variably configured to support different components having different geometries.

3. The system according to claim 2, wherein: The component installation tool includes: a tool frame capable of being coupled to the tool mounting plate of the operator; at least one shaft assembly supported on the tool frame; Each shaft assembly includes: at least one trunnion, a shaft supported on said at least one trunnion, At least one gripping member is mounted on the shaft and actuatable to supportably engage the component.

4. The system according to claim 3, wherein: The at least one shaft assembly includes a first shaft assembly and a second shaft assembly supported on the tool frame.

5. The system of claim 3, wherein: Each shaft assembly includes a plurality of gripping members positioned at different circumferential locations about the shaft; wherein gripping members positioned at different circumferential positions about the shaft are configured to engage components having different geometries; and each shaft is rotatable relative to the tool frame about the longitudinal axis of the shaft, whereby selected gripping members are positioned to engage the component by rotation of the corresponding shaft.

6. The system according to claim 3, wherein: The at least one gripping member includes a plurality of gripping members configured as air actuators adapted to sealingly engage the component when vacuum pressure is supplied to the air actuators.

7. The system of claim 6, wherein: Each shaft assembly includes a plurality of air manipulators positioned at different circumferential locations about the shaft; wherein the air manipulators at different circumferential locations about the shaft are configured to engage components having different geometries; and Each shaft is rotatable relative to the tool frame about a longitudinal axis of the shaft, whereby a selected air manipulator is positioned for engagement with the component by rotation of the corresponding shaft.

8. The system according to claim 7, further comprising: A locking assembly is provided on the tool frame and is operable to lock the shaft against rotation relative to the tool frame.

9. The system according to claim 7, further comprising: At least one passageway passes through the shaft and is configured to provide selective communication between a source of vacuum pressure and at least one air actuator, whereby vacuum pressure is provided to the air actuator when the air actuator is positioned to engage the component.

10. The system according to claim 1, wherein: The operator includes: at least three linkage mechanisms coupled between the operator base and the tool mounting plate; Each linkage has a first end pivotally coupled to the tool mounting plate; Each linkage has a second end opposite the first end and coupled to the operator base for controllable movement along at least one translation axis in a plane parallel to the operator base.

11. The system according to claim 10, wherein: The at least three linkage mechanisms have a fixed longitudinal length.

12. The system of claim 10, further comprising: At least one actuator is disposed between the second end of each respective linkage and the operator base.

13. The system according to claim 12, wherein: The at least one actuator includes a first actuator and a second actuator disposed between the second end of each respective linkage and the operator base.

14. The system according to claim 13, wherein: The first actuator associated with each linkage is a linear actuator arranged to control movement of the respective second end in a first direction, and the second actuator is a linear actuator arranged to control movement of the respective second end in a second direction orthogonal to the first direction.

15. A method of manipulating components to be assembled into a product on an assembly line, the method comprising: receiving the component on a component installation tool in a first retracted position spaced from the assembly line, wherein the component installation tool is in a first posture adapted to facilitate receiving or handling the component; as well as moving the component on the component installation tool in a direction toward the assembly line to a second working position in which the component installation tool is in a second posture suitable for facilitating attachment of the component to the product; in: The component installation tool is supported on a multi-axis manipulator having a manipulator base; and Moving the component on the component installation tool to the second working position includes moving the operator base from a first posture at the first retracted position to a second posture having a different orientation at the second working position.

16. The method according to claim 15, wherein: The component installation tool includes at least one air actuator configured to sealingly engage the component using vacuum pressure; and The method includes selectively providing vacuum pressure to the at least one air manipulator.

17. The method according to claim 16, wherein: The at least one air manipulator comprises a plurality of air manipulators configured to sealingly engage components having different geometries; and The method includes selectively indexing at least one of the plurality of air manipulators into a position and orientation for sealingly engaging the component.

18. The method according to claim 17, further comprising: Cooperating with the indexing is the selective provision of vacuum pressure to the at least one air operator.

19. The method of claim 15, further comprising at least one of the following: adding a sub-component to the component while the component is supported on the component installation tool in the first retracted position; or A manufacturing process is performed on the component while the component is supported on the component installation tool in the first retracted position.

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