Automatic clip application system for feeding cartridges

Abstract

The present application relates to an automatic clip application system for feeding boxes. An automatic clip application system for assembling clips (1) in an automotive assembly line, the automatic clip application system comprising a box receiving station (20) for receiving at least one box (11) pre-loaded with a plurality of clips (1). The clips in the box are arranged in the same orientation. A dispensing opening dispenses the clips (1) one at a time from the box (11), and a robotic member (10) is programmed to pick up the clips (1) one at a time after they are dispensed from the dispensing opening and to fasten each clip (1) in place in an automotive assembly.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to improvements in relation to an automated system for applying wiring harness fixing clips during assembly of a vehicle. BACKGROUND

[0002] Fixing clips are used in vehicles to hold wiring harnesses in place to ensure that they are correctly positioned and pass through bulkhead fittings etc so that they are not damaged or cut during use. This is achieved by using a robot which applies each clip in turn to the required location, but it is important that each clip is fitted by the robot in the correct way and also in the correct orientation so that the wiring harness can be automatically secured to the clip.

[0003] According to systems known in the prior art, this is achieved by each robot having a dedicated sorting system which is heavily fed with clips. In the prior art bowl feed system, unsorted clips are received in a bowl from which they are fed into a sorting channel where they are manipulated into a set orientation before being fed to the robot. The robot is programmed to take the clips one at a time, the clips being presented in a consistent orientation so that the robot can be programmed with a consistent set of movements to secure the clip in the correct location and orientation.

[0004] However, the prior art systems have the disadvantage that each robot must be equipped with a device to sort the clips which is both complex and expensive. This results in higher costs, increased maintenance time and costs and a larger space taken up by the equipment. SUMMARY

[0005] According to the present disclosure, there is provided an automated clip application system for fitting clips in a vehicle assembly line, the system comprising: a cartridge receiving station for receiving at least one cartridge pre-loaded in use with a plurality of clips, each of the plurality of clips being arranged in the same orientation; a dispensing opening for dispensing the clips from the cartridge; a gripping member movable between a first position in which the gripping member engages the dispensing opening to grip a clip positioned at the dispensing opening and a second position in which the gripping member is withdrawn from the end of the dispensing opening to position the gripped clip spaced apart from the dispensing opening; and a robotic member programmed to pick the clip from the gripping member when the clip is in the second position and to secure the clip in place in the assembly.

[0006] The advantages of the automated gripper application system according to this disclosure are that the use of a box-based feeding system enables multiple robots to reliably feed grippers from a single bowl feeder unit in a fixed configuration and orientation, thereby reducing cost and space requirements and increasing operational speed. Furthermore, using a box to transfer grippers from the sorting system to the application system allows the grippers to be manipulated, particularly reversed before being loaded into the application system.

[0007] The gripping member may include a pair of spring-loaded claws biased towards each other into a closed position. When the gripping member moves from its second position to its first position, pressing the claws against the clamp, the claws overcome the spring-loaded biasing force and are pushed away, causing the clamp to engage between the claws and be gripped by them. When the gripping member returns to the second position, the clamp is retained in the claws. Alternatively, the claws may be pneumatically or hydraulically opened and closed.

[0008] Preferably, the system includes a distribution channel having a first end and a second end, the first end being aligned with a clip in a box that is installed on the box receiving station during use, and the second end being aligned with a first position of the gripping member, the gripping member gripping the clip one at a time from the second end of the distribution channel.

[0009] Preferably, a door component is disposed at the second end of the distribution channel for controlling the passage of clamps exiting the distribution channel.

[0010] Preferably, the gripping member grips each clamp by means of its bottom end, which in use forms the end of the clamp that is inserted into the mounting opening, such that the other end is presented to engage with the robot component.

[0011] Preferably, the box or each box is mounted on the box receiving portion at an angle, such that the outlet end of each box is at the lowest point, so as to enable gravity feeding of the clamp from the box outward.

[0012] Multiple boxes are advantageously loaded onto the box receiving station in a vertically stacked arrangement. The box aligned with the system's distribution channel and located at the bottom of the stack can be translated along the distribution channel to align with a distribution opening for dispensing a clip from the box at the first end. Preferably, other boxes in the plurality of boxes are biased downwards such that when a box is removed from the bottom of the stack, the remaining boxes in the stack automatically move downwards to replace the removed box.

[0013] The present disclosure also provides a clip sorting assembly comprising: a bowl feeder for receiving and sorting clips into a loading channel in a fixed orientation, such that all clips in the loading channel are in the same orientation and configuration; a box loading station having a loading area for receiving an empty box aligned with the loading channel to load clips from the loading channel into the empty box; and a gate member associated with the loading channel for controlling passage of clips from the dispensing channel into a box located at the loading area.

[0014] Preferably, the box loading station is sized and configured to receive a plurality of boxes in a vertical stack adjacent the loading area, the assembly further comprising an actuator for moving a box from the bottom of the vertical stack into the loading area, the plurality of boxes being biased towards the bottom of the stack such that when a box is moved into the loading area, an adjacent box in the stack replaces it at the bottom of the stack.

[0015] The present disclosure still further provides a method of supplying clips to an automatic clip application system, the method comprising: sorting a plurality of clips using a clip sorting assembly according to the present invention; loading the clips into a plurality of boxes located in the box loading station; inverting the plurality of boxes; loading the inverted boxes into the box receiving station of the automatic clip application system of the present disclosure; and assembling the clips from the boxes one at a time using the robotic member. BRIEF DESCRIPTION OF DRAWINGS

[0016] In order that the present disclosure can be well understood, embodiments thereof will now be described by way of example with reference to the accompanying drawings in which:

[0017] Figure 1a Perspective view of a fixed clip of the type that can be used with the present disclosure;

[0018] Figure 1b Side view of a fixed clip of the type that can be used with the present disclosure; Figure 1a

[0019] Figure 2a Top view of an empty box for use with the present invention;

[0020] Figure 2b Top view of a box loaded with clips of the type that can be used with the present disclosure; Figure 2a

[0021] End view of a box of the type that can be used with the present disclosure; Figure 2c Figure 2a

[0022] Figure 3 ​​​A top view of a portion of the automatic gripper application system of this disclosure when the empty gripper component is in the second position;

[0023] Figure 4 for Figure 3 A top view of a portion of the automatic clamping system with the gripper component in the first position;

[0024] Figure 5 for Figure 3 A top view of a portion of the automatic clamping system in which the gripper component returns to its first position together with the clamp from the box;

[0025] Figure 6 for Figure 3 A top view of the automatic gripper application system in the case where the robot component is positioned to remove the gripper from the grasping component;

[0026] Figure 7 for Figures 2a to 2c A first isometric view of the clamp application system in the case where the gripper member grips the clamp in its first position;

[0027] Figure 8 for Figure 7 The second isometric view of the system;

[0028] Figure 9 for Figure 7 The system is loaded with a third isometric view of both full and empty boxes; and

[0029] Figure 10 An isometric view of the bowl feeder with a box loading system according to the present invention. Detailed Implementation

[0030] First refer to Figure 1a The figure shows a type of fastening clip 1 that can be used with this disclosure, which is known in the prior art. Clip 1 has a lower end 1a and an upper end 1b. The lower end 1a is inserted into a hole of complementary size during use to secure the clip in place. The upper end 1b has a mounting structure 4 formed thereon, by means of which cables, etc. (not shown), can be secured to the clip in a known manner (which will not be described in detail here). A dome-shaped cap 2 separates the upper end 1b and the lower end 1a and acts as a stop to limit the distance by which the lower end 1a can be inserted into the mounting hole. The lower end 1a has a circumferential rib 3 formed on its outer surface, which is inclined away from the lower end 1a to facilitate insertion of the lower end 1a into the mounting hole, but to prevent removal of the lower end 1a from the mounting hole in a known manner.

[0031] The mounting structure 4 located on the upper end 1b of the clip 1 is formed by a pair of spaced-apart posts 4a, 4b. A bridging member 4c extends between the posts 4a, 4c in a spaced-apart relationship with the cap 2 to define a tunnel 5 between the mounting structure 4 and the cap 2, through which a fixing strap, such as a cable tie, can circulate. Figure 1a As can be clearly seen, the length of mounting structure 4 is greater than its width, which is important for the correct orientation of the clips described below.

[0032] The top of the bridging member 4c is flat, allowing the clip 1 to be placed in a stable, inverted orientation, with the flat top of the bridging member 4c resting at the bottom and the lower end 1a of the clip pointing statically upwards. This configuration of the clip makes it the most stable static orientation of the clip, and therefore the most likely orientation to be adopted.

[0033] The clip uses, for example Figure 6 The robotic arm 10 shown is applied during automation. The robotic arm 10 picks up clamps 1 one at a time by gripping the mounting structure 4 located on the upper end 1b of the clamp and inserting the lower end 1a of the clamp into the mounting hole in the correct rotational position, ensuring that the tunnel 5 in the clamp faces the correct direction. Therefore, it is important not only to ensure that the robotic arm picks up each clamp 1 through its mounting structure 4, but also to ensure that the clamp 1 is correctly rotated about its longitudinal axis, so that the clamps are inserted into place sequentially with the tunnel 5 correctly oriented.

[0034] In this disclosure, similar to the prior art listed above, a large quantity of clips are fed to a sorting assembly, particularly as... Figure 10 The bowl-type feeder shown separates the clamps into a single line in a spiral channel around the clamp bowl 101 or reservoir. The bowl and channel are vibrated to agitate the clamps, pushing them into the most stable orientation described above, i.e., upside down, with the flat top of the bridging member 4c resting at its lowest point. As the clamps advance along the spiral channel, they pass through an obstruction portion in the channel, which forms a contraction portion only wide enough to allow a correctly oriented clamp to pass through. The obstruction portion extends inward from the outer wall of the channel such that each clamp passing through the contraction portion is pushed toward the inner edge of the unobstructed channel, thus allowing the clamp to fall and return to the clamp reservoir. A correctly oriented clamp can pass through the obstruction portion without falling off the inner edge; however, due to the geometry of the clamps, any clamp that is not correctly oriented will lose balance as it passes through the contraction portion and tip back into the clamp reservoir from the inner edge. Once past the contraction section, the clips pass through a funnel-shaped opening into an outlet channel 102 with a longitudinal groove at the bottom, the size of which is designed to interact with the mounting structure 4, on which each of the inverted clips is located at the bottom. (As from...) Figure 1a and Figure 1bIt will be seen that the width 'a' of the mounting structure is shorter than the length 'b', and that the dimensions of the recess in the bottom of the outlet channel are designed to fit with a tolerance with the width 'a' of each clip's mounting structure 4, so that when the clip is oriented with its bridge member 4c aligned with the longitudinal axis of the outlet channel, the clip can only enter the outlet channel. The funnelled entrance to the outlet channel 102, which has a corresponding funnelled entrance to the outlet channel recess, cam acts with the outer edges of the mounting structure 4, so that any clip which has not been correctly aligned with its mounting structure 4 will be rotated into the correct orientation as it enters the outlet channel. Such a sorting system is well known in the art and will not be described in detail here.

[0035] Unlike the prior art approach of having a single sorting assembly feed a single robot, according to the present disclosure the outlet channel 102 of the sorting assembly feeds into a box filling station 103, where the sorted and aligned clips 1 are loaded into boxes 11 such as Figures 2a to 2c Each box 11 has a holding channel 12 which has a similar profile to that of the outlet channel of the sorting assembly, so that when a clip passes from the outlet channel into the loading channel 12 and is held therein, the orientation and alignment of the clip 1 as it was in the outlet channel is maintained. A door is provided at the end of the outlet channel to control passage of the clips, and once an empty box 11 is positioned in line with the outlet channel, the door opens to allow the clip to pass into the loading channel of the empty box 11, and once the box is full, the door closes to allow the full box to be removed and replaced with an empty one. Each box similarly includes a door 13 at least at one end of its loading channel which controls the entry and exit of clips therefrom, and once loading is complete, the door closes to prevent the clips from falling out of the loading channel during transport of the box. In the illustrated embodiment, the clips are loaded and unloaded from the same end 12a of the loading channel 12 with the other end 12b closed, and the door 13 in the box takes the form of a plastic clip which is removably inserted into one end of the loading channel 12. However, in alternative embodiments, a door can be provided at each end of the channel to allow loading and dispensing from opposite ends of the loading channel.

[0036] As will be seen from the drawings Figure 2c It will be seen that the width of the loading channel of the box is reduced at the top of the channel by means of opposing flanges 14 which extend inwardly from the top of the side walls of the loading channel to overlap the cap 2 of the clip and form an undercut 15 into which the opposing side of the cap 2 engages, thereby preventing the loaded clip from falling out of the top of the loading channel 12 during transport of the box 11.

[0037] It will be appreciated that the sorting assembly can be provided with a plurality of outlet channels, all of which feed from the same bowl channel, thereby allowing a plurality of boxes to be filled simultaneously.

[0038] To maximize efficiency, the cartridge filling station 103 includes a cartridge storage area 104 adjacent the exit passage 102 that can receive a plurality of empty cartridges 11 stacked vertically one on top of the other to form an empty cartridge stack 105a. The bottom cartridge 11 located in the empty stack 105a is moved to a filling position 105b aligned with the exit passage 102 where the bottom cartridge is loaded with clips 1 and then moved to a filled cartridge stack 105c where the filled cartridges are similarly stacked one on top of the other with each new filled cartridge added to the bottom of the stack. The weight of the empty cartridges 11 located in the empty stack causes the cartridges to fall one at a time as it is removed for filling, although other options such as spring biased springs, hydraulic actuators, etc. are possible. In this manner, once a cartridge is removed from the empty stack 105a into the filling position 105b, the adjacent cartridge automatically replaces it in the filling position. A pneumatic actuator or the like moves the cartridges.

[0039] The filled cartridge stack 105c is then moved to a dispensing station 20 adjacent the assembly robot 10 as shown in Figures 3 to 9 The filled cartridge stack 105c is then moved to a dispensing station 20 adjacent the assembly robot 10 as shown in

[0040] The dispensing station 20 includes a cartridge receiving area 22 for receiving a plurality of filled cartridges 11 in a vertically stacked one on top of the other manner. The receiving area is divided into two sections: a filled stack section 22a as shown on the left in Figure 8 and Figure 9 and an empty stack section 22b as shown on the right in Figure 8 and Figure 9 The cartridge located at the bottom of the filled stack section 22a is in a dispensing station 22c from which clips 1 can be dispensed from the cartridge as described below. Once the bottom cartridge has been emptied of clips 1, a pneumatic actuator (not shown) removes the cartridge from the dispensing station 22c at the bottom of the filled stack section 22a and moves it to the empty stack section 22b where the existing stack is lifted and the newly emptied cartridge 11 is added to the bottom.

[0041] From the foregoing description, it will be appreciated that the cartridges 11 are filled with the loading passage oriented so that the clips 1 are loaded upside down into the loading passage 12, i.e. the mounting structure 4 is lowermost and the insertion end la of the clip points upward. To facilitate presenting the clips correctly to the assembly robot 10, the cartridges 11 are loaded upside down into the cartridge receiving area 22 of the dispensing station 20, i.e. the insertion end la of the clips 1 is lowermost so that the mounting structure 4 of each clip is uppermost, each clip 1 is suspended by the engagement of its cap 2 with the longitudinal flanges 14 which, as described above, protrude into the loading passage 12 from both sides.

[0042] AsFigure 8 and Figure 9 As shown in Figure 1 1, the cartridge 1 1 is placed on the cartridge receiving area 22 at an angle such that the outlet end is lowermost, thus the clips 1 are urged towards the outlet end under gravity.

[0043] Due to the way the clips 1 are loaded into the cartridge 1 1, there will typically be some random overlap between the caps 2 of adjacent clips, with the cap of one clip 1 overlying or underlying the cap 2 of an adjacent clip on each side. This is found to potentially hinder robotic clean pick of the end clips. To overcome this, the dispensing station 20 includes a gripper 21 arranged adjacent the outlet end 12a of the loading channel 12 of the cartridge 1 1. The gripper 21 has a pair of pneumatically actuated jaws 23 which are pneumatically moved from a closed position to an open position to allow the jaws 23 to press around the ribs 3 of the lower end 1 a of a clip 1 so as to grip it between the jaws 23. The gripper is then pneumatically actuated to move from a first position Figure 3 ) to a second position Figure 4 ) in which, in the second position, the gripper is located adjacent the end 12a of the loading channel 12 with the jaws 23 engaging an adjacent clip 1 to grip it. The gripper 21 is then retracted to its first position, with the clip 1 held within its jaws 23, so as to move the clip 1 away from the cartridge 1 1 and dispensing station, from which position the clip 1 can be easily picked up by the robotic arm 10 for attachment in place. The process is repeated each time the robotic arm 10 removes a clip 1 from the gripper 21, such that a continuous supply of clips 1 is available to the robotic arm.

[0044] Once the cartridge 1 1 in the dispensing station 22C is empty, it is slid to the right (see Figure 8 ) to the empty stack portion 22B, where it is added to the bottom of the empty stack, which allows the next full cartridge 1 1 to take its place and continue the process.

[0045] From the foregoing it will be appreciated that the use of the cartridge-based feed system of the present disclosure enables a single, appropriately sized sorting system to be used to supply a plurality of assembly robots. Furthermore, the use of cartridges to transport the sorted clips enables the clips to be easily flipped over once loaded, which facilitates further processing of the clips by the robots. Although the present disclosure has been described in conjunction with a pneumatically-based system, it will be appreciated that other actuation systems such as hydraulic systems can also be used.

Claims

1. An automatic clip application system for assembling a clip in an automotive assembly line, the automatic clip application system comprising: a cartridge receiving station for receiving at least one cartridge pre-loaded in use with a plurality of clips each arranged in the same orientation; a dispensing opening for dispensing the clips from the cartridge; and a robotic member programmed to pick up the clips one at a time after they are dispensed from the dispensing opening and to secure each clip in place in assembly, the system further comprising a gripping member movable between a first position in which it engages the dispensing opening to grip a clip positioned at the dispensing opening and a second position in which it is withdrawn from the dispensing opening to position the gripped clip spaced apart from the dispensing opening, wherein the robotic member is configured to pick up the clip from the gripping member when the gripping member is in the second position.

2. The automatic clip application system of claim 1, wherein, The gripping member comprises a pair of jaws actuable to move between a closed position and an open position, the gripping member being configured to move from its second position to its first position with the jaws open so that a clip located in the dispensing opening is engaged between the jaws and then the jaws can be closed around the clip to retain it therein when the gripping member is withdrawn to the second position.

3. The automatic clip application system of claim 2, wherein, The jaws are pneumatically actuated to move between the open and closed positions.

4. An automatic clip application system as claimed in any one of claims 1 to 3, further comprising a dispensing channel having a first end aligned with a clip holding channel in a cartridge positioned at a clip dispensing station of the system in use and a second end forming the dispensing opening.

5. An automatic clip application system as claimed in claim 4, further comprising a gate member at the second end of the dispensing channel for controlling passage of clips out of the dispensing channel.

6. The automatic clip application system of any one of claims 1-3 or 5, wherein, The gripping member is configured to grip each clip by means of a bottom end of the clip which in use constitutes an end of the clip inserted into a mounting opening with the other end presented for engagement by the robotic member.

7. The automatic clip application system of any one of claims 1-3 or 5, wherein, The or each cartridge is mounted on the cartridge receiving station at an inclination so that an outlet end of each cartridge is lowermost to enable clips to be fed outwards from the cartridge by gravity.

8. The automatic clip application system of any one of claims 1-3 or 5, wherein, A plurality of cartridges are loaded onto the cartridge receiving station in a vertically stacked one above the other manner with the cartridge at the bottom of the stack aligned with the dispensing opening so that clips can be dispensed from the cartridge.

9. The automatic clip application system of claim 8, wherein, The remaining cartridges are biased downwardly so that when the cartridge from the bottom of the stack is removed, an adjacent cartridge automatically moves to the bottom of the stack and into alignment with the dispensing opening.

10. The automatic clip application system of claim 8, wherein, The cartridge receiving station further comprises an empty cartridge stacking portion to which the cartridge aligned with the dispensing opening can be moved from the dispensing opening, in which empty cartridges are stacked in a vertically stacked one above the other manner.

11. A method of supplying clips to an automated clip application system, the method comprising: classifying a plurality of clips using a clip classifying and loading assembly, the clip classifying and loading assembly comprising: a feeder for receiving and classifying clips in a fixed orientation into a loading channel such that all clips in the loading channel are in the same orientation and configuration; a cartridge loading station having a loading area for receiving an empty cartridge aligned with the loading channel to load clips from the loading channel into the empty cartridge; and a gate member associated with the loading channel for controlling passage of clips from the loading channel into a cartridge located in the loading area; loading the clips into a plurality of cartridges located in the cartridge loading station; inverting the plurality of cartridges; loading the inverted cartridges into the cartridge receiving station of the automated clip application system of any one of claims 1 to 3, 5, 9 or 10; and assembling the clips from the cartridges one at a time using the robotic member.

12. A method of supplying clips to an automated clip application system, the method comprising: classifying a plurality of clips using a clip classifying and loading assembly, the clip classifying and loading assembly comprising: a feeder for receiving and classifying clips in a fixed orientation into a loading channel such that all clips in the loading channel are in the same orientation and configuration; a cartridge loading station having a loading area for receiving an empty cartridge aligned with the loading channel to load clips from the loading channel into the empty cartridge; and a gate member associated with the loading channel for controlling passage of clips from the loading channel into a cartridge located in the loading area; loading the clips into a plurality of cartridges located in the cartridge loading station; inverting the plurality of cartridges; loading the inverted cartridges into the cartridge receiving station of the automated clip application system of any one of claims 1 to 3, 5, 9 or 10; and assembling the clips from the cartridges one at a time using the robotic member.

13. A method of supplying clips to an automated clip application system, the method comprising: classifying a plurality of clips using a clip classifying and loading assembly, the clip classifying and loading assembly comprising: a feeder for receiving and classifying clips in a fixed orientation into a loading channel such that all clips in the loading channel are in the same orientation and configuration; a cartridge loading station having a loading area for receiving an empty cartridge aligned with the loading channel to load clips from the loading channel into the empty cartridge; and a gate member associated with the loading channel for controlling passage of clips from the loading channel into a cartridge located in the loading area; loading the clips into a plurality of cartridges located in the cartridge loading station; inverting the plurality of cartridges; loading the inverted cartridges into the cartridge receiving station of the automated clip application system of any one of claims 1 to 3, 5, 9 or 10; and assembling the clips from the cartridges one at a time using the robotic member.

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