System and method for installing decorative moulding

Abstract

A tool is configured to mount a decorative molding at a mounting site. The tool comprises: a first coupling member configured to couple the decorative molding to the tool; a second coupling configured to couple the tool to the mounting site; and an actuator configured to move the decorative molding away from the first coupling and onto the mounting location when the tool is coupled to the mounting location with the second coupling.

Description

[0001] The information provided in this section is for the purpose of presenting the context of the present disclosure generally. From the description in this section, the work of the currently named inventors and aspects that may not constitute prior art at the time of filing should neither be expressly nor impliedly considered as prior art of the present disclosure.

[0002] The present disclosure relates to systems and methods for installing decorative moldings, such as interior and exterior vehicle trim moldings.

[0003] Decorative moldings are typically installed by hand. For example, an operator will manually position the decorative molding at the installation site. Then, the operator will manually apply an insertion force to the decorative molding to move the coupling of the decorative molding into engagement with the coupling at the installation site, thereby securing the decorative molding in place. Summary of the Invention

[0004] The present disclosure includes, among various features, a tool configured to install a decorative molding at an installation site. The tool includes: a first coupling configured to couple the decorative molding to the tool; a second coupling configured to couple the tool to the installation site; and an actuator configured to move the decorative molding away from the first coupling and onto the installation site when the tool is coupled to the installation site using the second coupling.

[0005] In other features, the tool includes a bracket to which the first coupling member, the second coupling member, and the actuator are mounted.

[0006] In other features, a balancer is configured to cooperate with the bracket to mount the bracket to a suspension rail and facilitate manual positioning of the bracket.

[0007] In other features, the decorative molding is a vehicle decorative molding and the installation site is on a vehicle.

[0008] In other features, the first coupling includes a vacuum chuck.

[0009] In other features, the second coupling member includes a vacuum suction cup.

[0010] In other features, the actuator includes a short-stroke cylinder.

[0011] In other features, a proximity sensor is configured to measure the proximity of the tool to the installation site.

[0012] In other features, a control panel is configured to receive manual input for operating the first coupling and the actuator.

[0013] Among other features, a controller is configured to: in response to a first input entered by a user at a control panel, enable a first coupling to couple a decorative molding to a tool; determine a distance of the tool to an installation site based on a proximity input received by the controller from a proximity sensor included with the tool; and, when the tool is within a predetermined distance of the installation site, enable a second coupling to connect the tool to the installation site.

[0014] Among other features, the controller is configured to enable an actuator and deactivate the second coupling in response to a second input entered by the user at the control panel to disconnect the tool from the installation site.

[0015] Among other features, the tool is configured to be mounted to a robotic end effector.

[0016] Among other features, a controller is configured to: move the robotic end effector to position the first coupling against the decorative molding and enable the first coupling to couple the tool to the decorative molding; move the robotic end effector to align the decorative molding with the installation site based on an alignment input received by the controller from an alignment sensor of the tool; determine a distance of the tool to the installation site based on a proximity input received by the controller from a proximity sensor of the tool; when the decorative molding is aligned with the installation site based on the alignment input and the tool is within a predetermined distance of the installation site based on the proximity input from the controller, enable the second coupling to connect the tool to the installation site; enable the actuator to urge the decorative molding to cooperate with the installation site; and, deactivate the second coupling to disconnect the tool from the installation site.

[0017] Among other features, the controller is configured to: receive an actuation input from the actuator identifying an actuation distance of a rod of the actuator; determine based on the actuation distance whether the decorative molding is successfully installed on the installation site; and, re-enable the actuator after determining that the decorative molding is not successfully installed on the installation site.

[0018] The present disclosure also includes a tool configured to install a decorative molding at an installation site. The tool includes: a first coupling configured to couple the decorative molding to the tool; a second coupling configured to couple the tool to the installation site; a proximity sensor configured to measure a distance between the tool and the installation site; an actuator configured to move the decorative molding away from the first coupling and to the installation site when the tool is coupled to the installation site by the second coupling; and, a controller configured to enable the second coupling to connect the tool to the installation site when, based on an input from the proximity sensor, the controller determines that the distance of the tool to the installation site is within a predetermined distance.

[0019] Among other features, the controller is further configured to, after the tool is coupled to the mounting site by the second coupling, enable the actuator to urge the decorative molding to cooperate with the mounting site.

[0020] Among other features, the controller is further configured to: receive an actuation input from the actuator that identifies an actuation distance of the rod of the actuator; determine based on the actuation distance whether the decorative molding is successfully installed on the mounting site; and, after determining that the decorative molding is not successfully installed on the mounting site, re-enable the actuator.

[0021] The present disclosure also includes, among various features, a method for installing a decorative molding at a mounting site. The method includes: moving a tool to cooperate with the decorative molding to connect the decorative molding to the tool; aligning the decorative molding at the mounting site with the tool; coupling the tool to the mounting site after aligning the decorative molding; installing the decorative molding on the mounting site by enabling the actuator of the tool to push the decorative molding away from the tool to cooperate with the mounting site; and separating the tool from the mounting site.

[0022] Among other features, the method includes reattempting to install the decorative molding on the mounting site in response to determining that the actuator has not fully extended.

[0023] Among other features, the method includes moving the tool with a robotic arm.

[0024] From the detailed description, the claims, and the drawings, other application areas of the present disclosure will become apparent. The detailed description and the specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present disclosure will be more fully understood from the detailed description and the drawings, in which:

[0026] Figure 1 An installation system for a decorative molding according to the present disclosure is shown;

[0027] Figure 2 Shown Figure 1 The use of the installation system for installing a fender decorative molding on a mounting site on a vehicle fender;

[0028] Figure 3 Shown Figure 1 The operation of the installation system to move the fender decorative molding to the mounting site;

[0029] Figure 4 The tool of the installation system mounted on the end effector of a robotic arm is shown;

[0030] Figure 5 Disclosed is a method for installing a decorative molding at an installation site according to the present disclosure;

[0031] Figure 6A Disclosed is another method for installing a decorative molding at an installation site according to the present disclosure; and

[0032] Figure 6B is Figure 6A a continuation of the method of.

[0033] In the drawings, reference numerals may be reused to identify similar and / or identical elements. DETAILED DESCRIPTION

[0034] The present disclosure includes systems and methods for at least partially automating the installation of components. The systems and methods are adapted to install any suitable component at any suitable installation site. For example, the component may be or include a decorative molding, and the installation site may be on a vehicle, such as on the exterior or interior of a vehicle. The decorative molding may be any suitable decorative molding, such as any suitable Class A surface. The decorative molding may include, for example, fender decorative moldings, door decorative moldings, front decorative moldings, rear decorative moldings, lip decorative moldings, vehicle spoilers, headlight decorative moldings, interior dashboard decorative moldings, and the like. The systems and methods of the present disclosure are also applicable to installing non-vehicle decorative moldings at any suitable non-vehicle installation site.

[0035] Figure 1 Shown is an installation system 10 for installing a component at an installation site according to the present disclosure. The installation system 10 includes a tool 20. The tool 20 includes a bracket 22. The bracket 22 may be any suitable size and shape and may depend on the size and shape of the component to be installed. In Figure 1 the example of, the tool 20 includes a bracket 22 as a first bracket and a second bracket 24 extending at a right angle from the bracket 22. The tool 20 may have any suitable number of brackets arranged in any suitable orientation to facilitate the installation of the component. Referring to Figure 2 , the component is, for example, a decorative molding 210 configured to be installed on a vehicle fender 310. To facilitate the installation of the decorative molding 210, the tool 20 includes brackets 22, 24 arranged at a right angle, which is beneficial for the cooperation between the tool 20 and the decorative molding 210.

[0036] The tool 20 also includes a plurality of first connectors configured to couple the decorative molding 210 to the tool 20. Any suitable connectors may be included, such as vacuum cups 30 configured as decorative molding connectors. Any suitable number of vacuum cups 30 may be included, and the vacuum cups 30 may be positioned at any suitable location on the tool 20. In the illustrated example, the vacuum cups 30 are spaced along and between brackets 22 and 24.

[0037] The tool 20 also includes a plurality of second connectors configured to couple the tool 20 to any suitable mounting site. Figure 2 and 3 An exemplary mounting site 310 in the form of a vehicle fender is shown. Any suitable connectors may be included, such as vacuum suckers 50 configured as tool connectors. Any suitable number of vacuum suckers 50 may be included, and the vacuum suckers 50 may be positioned at any suitable location on the tool 20. In the illustrated example, the vacuum suckers 50 are mounted on brackets 22 and 24.

[0038] The tool 20 also includes one or more actuators 40. The actuator 40 is configured to push the decorative molding 210 off or otherwise move it onto the vacuum cups 30 and onto the mounting site 310 when the tool 20 is coupled to the mounting site 310. The actuator 40 may be configured in any suitable manner to push the decorative molding 210 off the tool 20. For example, the actuator 40 may be configured as a short-stroke cylinder with a push rod 42. The actuators 40 are spaced around the brackets 22, 24 and may be arranged between the brackets 22, 24 to provide a substantially uniform actuating force on the decorative molding 210 to push the decorative molding 210 onto the mounting site 310.

[0039] The system 10 also includes a control panel 70 that may be mounted to or connected to the tool 20. The control panel 70 includes any suitable user interface, such as buttons 72, configured to be used by an operator 410 to operate the installation system 10. The control panel 70 also includes a controller 80. In response to an input from the operator 410 via the buttons 72, the controller 80 is configured to enable and disable the vacuum cups 30, the actuators 40, and the vacuum suckers 50, as further explained herein. The controller 80 may be included in the control panel 70 or otherwise mounted on the tool 20. The controller 80 may also be spaced from the tool 20 and connected in any suitable manner to the vacuum cups 30, the vacuum suckers 50, the actuators 40, and the sensors of the tool 20, all of which are described herein.

[0040] The tool 20 also includes a proximity sensor 60 configured to identify the distance between the tool 20 and the mounting site 310. The proximity sensor 60 works in conjunction with the controller 80. Based on the input from the proximity sensor 60, the controller 80 is configured to identify the distance between the tool 20 and the mounting site 310. When, based on the input from the proximity sensor 60, the controller 80 determines that the tool 20 is within a predetermined distance of the mounting site 310, the controller 80 is configured to enable the vacuum chuck 50 to secure the tool 20 to the mounting site 310.

[0041] As Figure 1 and 2 shown, the tool 20 can be suspended from a balancer 130, and the cable 132 of the balancer 130 is connected to the bracket 22 of the tool 20. The balancer 130 can also be suspended from any suitable rail 110 via a connector 120. Mounting the tool 20 on the rail 110 facilitates the operator 410 to move the tool 20 onto and from the mounting site 310, and to and from a picking area including one or more decorative moldings 210. For example, the weight of the decorative molding 210 and the tool 20 is supported by the balancer 130 and the rail 110, thereby reducing the workload of the operator 410.

[0042] Figure 3 Shown is the tool 20 connected to the mounting site 310 via the vacuum chuck 50. After the tool 20 is mounted on the mounting site 310, the operator 410 no longer needs to hold the tool 20. To install the decorative molding 210, the operator 410 inputs an installation command to the controller 80 via the control panel 70. In response, the controller 80 is configured to enable the actuator 40 to extend the piston rod 42 as Figure 3 shown, and the piston rod pushes the decorative molding 210 onto the mounting site 310, so that the first connector 212 of the decorative molding 210 cooperates with the second connector 312 of the mounting site 310. This cooperation between the first connector 212 and the second connector 312 can mount the decorative molding 210 on the mounting site 310.

[0043] Referring Figure 4 , the tool 20 can be mounted on a robotic arm 510, for example, on the end effector 512 of the robotic arm 510. The robotic arm 510 is configured to manipulate the tool 20 to pick up the decorative molding 210 from a pick-up position, manipulate the decorative molding 210 onto the mounting site 310, and install the decorative molding 210 as explained herein. In Figure 4 the configuration, the tool 20 also includes a first alignment sensor 62 and a second alignment sensor 64, each of which is configured to align the decorative molding 210 at the mounting site 310. InFigure 6A and 6B In the discussion of method 710, the operation of the robotic arm 510 mounting the decorative molding 210 is further described herein.

[0044] Figure 5 An exemplary method 610 according to the present disclosure is shown, which is for mounting a decorative molding 210 onto a mounting site 310 using a semi-automated process. At block 612, the controller 80 enables a vacuum chuck 30 (first coupler) configured as a decorative molding coupler in response to an input entered by an operator 410 via a control panel 70 to couple the decorative molding 210 to the tool 20. The tool 20 is initially moved to the decorative molding 210 by the operator 410, via the robotic arm 510, or in any other suitable manner. At block 614, the decorative molding coupler configured as the vacuum chuck 30 couples the decorative molding to the tool.

[0045] At block 616, the tool 20 with the decorative molding 210 coupled thereto is maneuvered to the mounting site 310, for example, by the operator 410, the robotic arm 510, or in any other suitable manner. At block 618, the proximity sensor 60 determines the proximity of the tool 20 relative to the mounting site 310. The proximity sensor 60 sends an input indicating the distance between the tool 20 and the mounting site 310 to the controller 80. When, based on the input from the proximity sensor 60, the controller 80 determines that the tool 20 is within a predetermined distance of the mounting site 310, at block 620, the controller 80 is configured to enable a vacuum suction cup 50 (second coupler) configured as a tool coupler to connect the tool 20 to the mounting site 310.

[0046] After the tool 20 is mounted to the mounting site by the vacuum suction cup 50, at block 622, the controller 80 is configured to enable the actuator 40 such that the piston rod 42 extends outward as Figure 3 shown. The rod 42 pushes the decorative molding 210 away from the tool 20 and onto the mounting site 310. The first connector 212 of the decorative molding 210 cooperates with the second connector 312 at the mounting site 310 to mount the decorative molding 210 onto the mounting site 310. After the decorative molding 210 is installed, at block 624, the controller 80 is configured to deactivate the vacuum suction cup 50 to separate the tool 20 from the mounting site 310. Then, the tool 20 can be ready to mount another decorative molding at another mounting site.

[0047] Figure 6A and 6B Another method 710 according to the present disclosure is shown, which includes using Figure 4Configured robotic arm 510 and tool 20. When a start command is received, controller 80 is configured to enable the vacuum chuck 30 of tool 20 at block 712. At block 714, controller 80 moves tool 20 to a pick-up position for storing the decorative molding 210 by actuating robotic arm 510. At block 716, controller 80 operates robotic arm 510 to move vacuum chuck 30 into cooperation with decorative molding 210, thereby connecting tool 20 to decorative molding 210. At block 718, controller 80 moves robotic arm 510 to position decorative molding 210 at the installation site 310. At block 718, controller 80 aligns decorative molding 210 with installation site 310 based on inputs received from alignment sensors 62, 64.

[0048] At block 720, controller 80 detects the proximity of tool 20 to installation site 310 based on an input from proximity sensor 60. When, based on an input from proximity sensor 60, controller 80 determines that tool 20 is within a predetermined distance from installation site 310, at block 722, controller 80 enables vacuum chuck 50 to connect tool 20 to the installation site. At block 724, controller 80 enables actuator 40 to extend its piston rod 42. When piston rod 42 extends, piston rod 42 pushes decorative molding 210 away from tool 20 and onto installation site 310. As Figure 3 shown, the first connector 212 of decorative molding 210 cooperates with the second connector 312 of installation site 310 to mount decorative molding 210 onto installation site 310.

[0049] Method 710 proceeds from block 724 to block 730. At block 730, controller 80 determines whether the installation of decorative molding 210 is successful. This determination can be made in any suitable manner. For example, based on an input from actuator 40, controller 80 is configured to identify any of piston rods 42 that have not fully extended. If all piston rods 42 have fully extended, then controller 80 is configured to consider the installation successful. Given a successful installation, controller 80 proceeds to block 732. At block 732, controller 80 is configured to deactivate vacuum chuck 50 to separate tool 20 from installation site 310. At block 734, controller 80 is configured to move robotic arm 510 and end effector 512 back from installation site 310 to the pick-up position to retrieve another decorative molding for installation, or otherwise return to a predetermined original position.

[0050] If, based on the input from actuator 40, controller 80 determines that one or more of the piston rods 42 are not fully extended, then at block 730, controller 80 deems the installation unsuccessful. In the case of an unsuccessful installation, the controller proceeds from block 730 to block 750. At block 750, controller 80 records the unsuccessful installation attempt and then proceeds to block 752. At block 752, controller 80 determines whether the number of installation attempts has exceeded a predetermined limit. If the predetermined limit has not been exceeded, then method 710 proceeds to block 754. At block 754, controller 80 is configured to attempt the installation again. Method 710 returns from block 754 to block 724 and then back to block 730. At block 730, controller 80 again determines whether the installation is successful based on whether all of the piston rods 42 are not sufficiently extended. If the predetermined number of installation attempts is exceeded at block 752, then method 710 proceeds to block 760. At block 760, controller 80 generates an alert and pauses the installation operation. For example, an alert is generated to operator 410 to enable operator 410 to troubleshoot the installation.

[0051] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Thus, while the disclosure includes specific examples, the true scope of the disclosure should not be so limited since other modifications will become apparent after study of the drawings, the specification, and the appended claims. It should be understood that one or more steps in the methods can be performed in a different order (or concurrently) without altering the principles of the disclosure. Further, although each of the embodiments above is described as having certain features, any one or more of those features described with reference to any embodiment of the disclosure can be implemented in and / or combined with the features of any of the other embodiments, even if not explicitly described as such. In other words, the described embodiments are not mutually exclusive, and permutations of one or more of the embodiments with each other remain within the scope of the disclosure.

[0052] Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected", "engaged", "coupled", "adjacent", "next to", "on top", "above", "below", and "disposed". Unless explicitly described as "direct", when describing the relationship between a first and a second element in the foregoing disclosure, the relationship can be a direct relationship where no other intermediate elements exist between the first and second elements, but can also be an indirect relationship where one or more intermediate elements exist between the first and second elements (spatially or functionally). As used herein, the phrase "at least one of A, B, and C" should be interpreted to mean a logical "or" (A or B or C) using non-exclusive logic and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C".

[0053] In the drawings, the direction of an arrow, as indicated by the arrow, generally represents the flow of information of interest (e.g., data or instructions) being illustrated. For example, when element A and element B exchange various information, but the information transmitted from element A to element B is relevant to the illustration, the arrow can point from element A to element B. This one-way arrow does not imply that no other information is transmitted from element B to element A. Additionally, for the information sent from element A to element B, element B can also send a request for that information or an acknowledgment of the receipt of that information to element A.

[0054] In this application, the following definitions are included. The term "module" or the term "controller" can be replaced with the term "circuit". The term "module" can refer to any of the following, be part of any of the following, or include any of the following: an application specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores the code executed by the processor circuit; other suitable hardware components that provide the functionality; or a combination of some or all of the above, such as in a system on a chip.

[0055] A module can include one or more interface circuits. In some examples, the interface circuit can include a wired or wireless interface connected to a local area network (LAN), the Internet, a wide area network (WAN), or a combination thereof. The functionality of any given module of the present disclosure can be distributed among multiple modules connected via the interface circuit. For example, multiple modules can allow for load balancing. In other examples, a server (also referred to as remote or cloud) module can perform some functions on behalf of a client module.

[0056] As used above, the term "code" can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, data structures, and / or objects. The term "shared processor circuit" encompasses a single processor circuit that executes some or all of the code from multiple modules. The term "group processor circuit" encompasses a processor circuit that, in conjunction with additional processor circuits, executes some or all of the code from one or more modules. References to a multi-processor circuit encompass multi-processor circuits on discrete die, multi-processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above. The term "shared memory circuit" encompasses a single memory circuit that stores some or all of the code from multiple modules. The term "group memory circuit" encompasses a memory circuit that, in conjunction with additional memory, stores some or all of the code from one or more modules.

[0057] The term "memory circuit" is a subset of the term "computer-readable medium". As used herein, the term "computer-readable medium" does not encompass transitory electrical or electromagnetic signals propagated through a medium (such as on a carrier wave). Thus, the term "computer-readable medium" can be considered tangible and non-transitory. Non-limiting examples of non-transitory, tangible computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or mask read-only memory circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog or digital tape or hard disk drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0058] The apparatuses and methods described in this application can be implemented, in part or in whole, by a special-purpose computer created by configuring a general-purpose computer to execute one or more specific functions included in a computer program. The above functional blocks, flowchart components, and other elements serve as software specifications, which can be converted into a computer program by the routine work of a skilled technician or programmer.

[0059] A computer program includes processor-executable instructions stored on at least one non-transitory, tangible computer-readable medium. The computer program can also include or rely on stored data. The computer program can include a basic input / output system (BIOS) that interacts with the hardware of the special-purpose computer, device drivers that interact with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, and the like.

[0060] A computer program can include: (i) descriptive text to be parsed, such as HTML (HyperText Markup Language), XML (eXtensible Markup Language), or JSON (JavaScript Object Notation); (ii) assembly code; (iii) object code generated from source code by a compiler; (iv) source code executed by an interpreter; (v) source code compiled and executed by a just-in-time compiler, and so on. For example, source code can be written using the syntax of languages including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Fortran, Perl, Pascal, Curl, OCaml, HTML5 (HyperText Markup Language, 5th Edition), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Visual Lua, MATLAB, SIMULINK, and to write source code.

Claims

1. A tool configured to install a decorative molding at an installation location, comprising: a first coupling member configured to couple the trim molding to the tool; a second coupling member configured to couple the tool to the mounting site; as well as An actuator is configured to move the trim molding away from the first coupling member and onto the mounting site when the tool is coupled to the mounting site using the second coupling member.

2. The tool according to claim 1, further comprising a bracket; in, The first link, the second link, and the actuator are mounted to the bracket.

3. The tool of claim 2, further comprising a balancer configured to work in conjunction with the bracket to mount the bracket to a hanging rail and facilitate manual positioning of the bracket.

4. The tool according to claim 1, wherein: The trim molding is a vehicle molding, and the mounting location is on a vehicle.

5. The tool according to claim 1, wherein: The first coupling member includes a vacuum head.

6. The tool according to claim 1, wherein: The second coupling member includes a vacuum suction cup.

7. The tool according to claim 1, wherein: The actuator includes a short-stroke cylinder.

8. The tool of claim 1, further comprising a proximity sensor configured to measure a proximity of the tool to the mounting site.

9. The tool of claim 1, further comprising a control panel configured to receive manual input for operating the first coupling and the actuator.

10. The tool of claim 1, further comprising a controller configured to: activating a first coupling to couple the trim molding to the tool in response to a first input entered by a user at the control panel; determining a distance from the tool to the installation site based on a proximity input received by the controller from a proximity sensor included with the tool; and When the tool is within a predetermined distance of the mounting site, the second coupling member is activated to connect the tool to the mounting site.

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