Component assembly system for assembling a component

Abstract

Component assembly system comprising: a first robot arm (30); a first subcomponent (16) defining a first plurality of guide bores (28); a first gripping element (26) attached to the first robot arm (30) for gripping the first subcomponent (16); a second robot arm (130) which is displaceable in the direction of the first robot arm (30); a second subcomponent (18) defining a second plurality of guide bores (128); a second gripping element (126) attached to the second robot arm (130) for gripping the second subcomponent (18); wherein the second robot arm (130) serves to align the first plurality of guide holes (28) adjacent the second plurality of guide holes (128) to thereby establish a starting position of the second subcomponent (18) relative to the first subcomponent (16) without releasing the second subcomponent (18) from the second gripping element (126); wherein the first robot arm (30) serves to align the first plurality of guide holes (28) adjacent the second plurality of guide holes (128) to thereby establish the home position without releasing the first subcomponent (16) from the first gripping element (26); a robot connection arm which serves to establish a connection between the first and the second subcomponent (16, 18), and a holding device (50) for supporting the first subcomponent (16) contains the following individual parts: a stand (52) spaced from the first robot arm (30) and second robot arm (130) having the following properties: a first end (54); a second end (154) spaced from the first end (54); and a longitudinal axis (56) extending between the first end (54) and the second end (154); a first arm (60) attached to the stand (52) at the first end (54), the first arm (60) being stationary relative to the second end (154); a first gripping element (62) attached to the first arm (60) and having the following properties: a first cover (68) defining a first plurality of channels (70) contained therein; and a first plurality of pins (40), each of the first plurality of pins (40) being retractable into and slidable from the corresponding one of the first plurality of channels (70); wherein each of the first plurality of pins (40) is initially retracted into the corresponding one of the first plurality of channels (70) in preparation for receiving the first subcomponent (16) when the first subcomponent (16) is spaced from the first plurality of pins (40); a second arm (160) attached to the post (52) between the first and second ends (54, 154), the second arm being displaceable along the post (52) relative to the first arm (60) along the longitudinal axis (56); and a second gripping element (162) attached to the second arm (160) having the following properties: a second cover (168) defining a second plurality of channels (170) therein; and a second plurality of pins (140), each of the second plurality of pins (140) being retractable into and slidable out of a corresponding one of the second plurality of channels (170); wherein each of the second plurality of pins (140) is initially retracted into the corresponding one of the second plurality of channels (170) in preparation for receiving the first subcomponent (16) when the first subcomponent (16) is spaced from the second plurality of pins (140).

Description

TECHNICAL FIELD

[0001] This invention relates to a component mounting system according to claim 1, as is essentially known from EP 2 824 526 A2.

[0002] From DE 10 2004 049 332 A1, for example, a method for the automated positioning of at least two components using a plurality of industrial robots is known, wherein a first positioning robot positions a first component in a first joining position and a second positioning robot positions a second component in a second joining position. It is provided that, during the positioning of the second component, the at least temporarily varying distance of the second component from the first component is determined by means of a sensor unit, and that, by means of a control unit connected to the sensor unit and to at least one positioning robot, a precise positioning of the components relative to one another in a respective joining position takes place through the controlled positioning of at least one positioning robot.

[0003] Further prior art can also be found in the documents US 4 691 905 A and US 7 204 481 B2. BACKGROUND

[0004] A manufacturing system typically moves, transforms, or manipulates workpieces, subassemblies, and / or sub-assemblies that require precise positioning and locating for manufacturing and assembly operations. For example, sheet metal parts, subassemblies, or sub-assemblies must be precisely positioned and locating to perform assembly, welding, and inspection operations in a body shop, a vehicle assembly plant, or on a production line for appliance, aircraft, furniture, and electronics components.

[0005] For this purpose, workpiece positioning fixtures are typically used. Workpiece positioning fixtures typically include a plurality of fixed pins designed to fit into a plurality of pilot holes defined by a workpiece, as well as one or more clamps that serve to hold the workpiece in place. Workpiece positioning fixtures are generally only used for a specific workpiece size and / or shape and usually need to be modified or rebuilt to position and hold a workpiece of a different size and / or shape. Typically, multiple workpiece positioning fixtures are required within a production facility to accommodate the wide range of workpieces and the variety of assembly and manufacturing operations. SUMMARY

[0006] According to the invention, a component assembly system is presented which is characterized by the features of claim 1.

[0007] Furthermore, a method for assembling a component is described. The method includes gripping a first subcomponent with a first gripping element. The first gripping element is attached to a first robot arm, and the first subcomponent defines a first plurality of guide bores. The method further includes gripping a second subcomponent with a second gripping element. The second gripping element is attached to a second robot arm, and the second subcomponent defines a second plurality of guide bores.Furthermore, the method includes, following the gripping, aligning at least one guide bore of the first plurality of subcomponents with at least one guide bore of the second plurality of subcomponents to thereby establish a starting position of the second subcomponent relative to the first subcomponent without releasing the first subcomponent from the first gripping element and without releasing the second subcomponent from the second gripping element. Following the alignment, the method includes establishing a connection between the first and second subcomponents using a connecting device attached to a robotic connecting arm to assemble the component.

[0008] The above features and advantages, as well as other features and advantages of the present invention, will become apparent from the following detailed description of the embodiment(s) and the best mode(s) for carrying out the described inventions with reference to the accompanying drawings and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 shows a schematic flow diagram of a method for assembling a component; Fig. Figure 2A shows a schematic representation of a perspective view of a component assembly system for the method of Fig. 1, including a first and a second robot arm, and a robot connecting arm; Fig. Figure 2B shows a schematic representation of a perspective view of another embodiment of the component mounting system of Fig. 2A, including a holding device; Fig. 3 shows a schematic representation of a side view of the holding device of the component mounting system of Fig. 2B; Fig. Figure 4 shows a schematic representation of a partial perspective view of a part of the component assembly system of Fig. 2B; Fig. 5 shows a schematic representation of a side view of the holding device of the Fig. 3; Fig. 6 shows a schematic representation of a partial perspective view of a part of a first subcomponent; Fig. Figure 7 shows a schematic representation of a partial perspective view of a part of a second subcomponent which is connected to the first component of the Fig. 6 can be connected; Fig. 8 shows a schematic representation of a side view of a first gripping element of the holding device of Fig. 3-5; Fig. Figure 9 shows a schematic representation of a cross-sectional view of the first gripping element of the Fig. 8 along section line 9-9; Fig. Figure 10 shows a schematic representation of an end view of the first gripping element of the Fig. 8; and Fig. 11 shows a schematic representation of a side view of a part of the component mounting system of the Fig. 2B. DETAILED DESCRIPTION

[0009] Referring to the figures, wherein like reference numerals refer to like elements, a method 10 for assembling a component 12 ( Fig. 2A and Fig. 2B) in Fig. 1 is presented in general terms. Furthermore, the Fig. 2A and Fig. 2B, a component assembly system 14 for use with the method 10 is generally illustrated. The component 12 can be manufactured from a first subcomponent 16 and a second subcomponent 18. In addition, the method 10 and the component assembly system 14 may be suitable for providing one-sided clamps or supports for the component 12 during manufacturing operations, such as welding, assembly, sub-assembly, picking, alignment, and the like. Therefore, the method 10 and the component assembly system 14 may be suitable for those manufacturing operations and environments that require precise positioning and placement of workpieces. The method 10 and the component assembly system 14 may be particularly suitable for components 12 with complex shapes or contours 20, 22 ( Fig. 3). For example, the method 10 and the component assembly system 14 may be suitable for the assembly, welding, and inspection operations in a body shop of a vehicle assembly plant or on a production line for appliance, aircraft, furniture, and electronic components.

[0010] The method 10 and component assembly system 14 may be suitable for manufacturing processes that involve the treatment of differently shaped or contoured surfaces 66, 166 ( Fig. 3). Therefore, the method 10 and the component assembly system 14 may be suitable during the placement of workpieces and / or assembly work for, for example, vehicles such as motor vehicles, construction machinery and rail vehicles; as well as for consumer goods such as appliances and furniture. In one embodiment, the component 12 may be a rear tailgate or liftgate of a motor vehicle, in which case the method 10 and the component assembly system 14 may enable flexible manufacturing processes that can handle different sized and shaped tailgates and liftgates without the need to change tools. Therefore, the method 10 and the component assembly system 14 may be particularly suitable during a model change.This means that the component assembly system 14 can simply be electronically reprogrammed during a model change instead of a physical retooling, and if a size or shape of the component 12 changes, this may only require changes to the software and no changes to the hardware.

[0011] Looking again at the Fig. 1, Fig. 2A and Fig. 2B, it can be seen that the method 10 comprises gripping 24 the first subcomponent 16 ( Fig. 2A and Fig. 2B) with a first gripping element 26 ( Fig. 2A and Fig. 2B). The first subcomponent 16 may, for example, be a panel designed as a tailgate or liftgate for a motor vehicle. Alternatively, the first subcomponent 16 may be an aircraft fuselage panel, a door panel for a consumer appliance, an armrest for a seat, or any other subcomponent designed to be connected or attached to another subcomponent. The first subcomponent 16 may be made of a suitable material, such as metal, plastic, a composite material, and the like. Further defined, as shown in Fig. 6, the first subcomponent 16 has a first plurality of guide bores 28.

[0012] As with regard to Fig. 2A and Fig. 2B, the first gripping element 26 is attached to a first robot arm 30 and can, regardless of the size or shape of the first subcomponents 16, optionally be used to grip 24 ( Fig. 1) of the first subcomponent 16. Therefore, the first gripping element 26 may include one or more cross braces 32 and cross beams 34 that support the first subcomponent 16 while the first robotic arm 30 picks up, grasps, and maneuvers the first subcomponent 16 from one position to another. The first robotic arm 30 may be a programmable mechanical arm, possibly composed of hand, wrist, elbow, and shoulder portions (not shown) that can be remotely controlled by pneumatics and / or electronics. The first robotic arm 30 may be, for example, a six-axis articulated robotic arm, a Cartesian robotic arm, a spherical or polar robotic arm, a SCARA robotic arm, and the like. The first robotic arm 30 may, for example, be a six-axis articulated robotic arm. The grasping 24 may therefore include,clamping the first subcomponent 16 between two or more clamps (not shown) during displacement or manipulation of the first subcomponent 16.

[0013] When considering the Fig. 3, it should be noted that procedure 10 also involves taking 36 ( Fig. 1) of the second subcomponent 18 with a second gripping element 126 ( Fig. 2A and Fig. 2B). The second subcomponent 18 is, for example, a reinforcing component that serves to reinforce and strengthen the first subcomponent 16. Alternatively, the second subcomponent 18 is a second panel, a fastening device, or any other subcomponent 16 that serves to be connected or fastened to the first subcomponent. The second subcomponent 18 may, if desired, be made of any suitable material and, moreover, of the same material or a different material than the first subcomponent 16, such as metal, plastic, a composite material, and the like. As can be seen from Fig. 7, the second subcomponent 18 further defines a second plurality of guide bores 128 configured for alignment with the first plurality of guide bores 28, as set forth in detail below.

[0014] Looking again at the Fig. 2A and Fig. 2B it can be seen that the second gripping element 126 is attached to a second robot arm 130 and is used to grip 36 ( Fig. 1) of the second subcomponent 18, regardless of the size or shape of the second subcomponent 18. Therefore, the first gripping element 126 may include one or more cross braces 32 and crossbeams 34 that support the second subcomponent 18 while the second robotic arm 130 picks up, grasps, and maneuvers the second subcomponent 18 from one position to another. The second robotic arm 130 may be a programmable mechanical arm, possibly composed of hand, wrist, elbow, and shoulder portions (not shown) that can be remotely controlled by pneumatics and / or electronics. The second robotic arm 130 may be, for example, a six-axis articulated robotic arm, a Cartesian robotic arm, a spherical or polar robotic arm, a SCARA robotic arm, and the like. Furthermore, the first robotic arm 30 and the second robotic arm 130 may be the same or different.The second robot arm 130 may, for example, be a six-axis articulated robot arm. Therefore, the grasping 36 may include clamping the second subcomponent 18 between two or more clamps (not shown) while translating or manipulating the second subcomponent 18.

[0015] As can be seen from the Fig. 2A and Fig. 2B, the component assembly system 14 includes the first robot arm 30, the first subcomponent 16 having the first plurality of guide holes 28 ( Fig. 6), and the first gripping element 26 attached to the first robot arm 30 and configured to grip the first subcomponent 16. The component assembly system 14 also includes the second robot arm 130, the second subcomponent 18, which defines the second plurality of guide bores 128 ( Fig. 7), as well as the second gripping element 126 attached to the second robot arm 130 and configured to grasp the second subcomponents 18.

[0016] Further consideration of the Fig. 2A and Fig. 2B, it can be seen that the second robot arm 130 is displaceable in the direction of the first robot arm 30. This means that the second robot arm 130 may move toward and away from the first robot arm 30 to displace the second subcomponent 18 relative to the first subcomponent 16 without releasing the first subcomponent 16 from the first gripping element 26 110 ( Fig. 1) and without releasing 110 the second subcomponent 18 from the second gripping element 126. In particular, the second robot arm 130 is used for aligning the first plurality of guide holes 28 ( Fig. 6) next to the second plurality of guide holes 128 ( Fig. 7) to thereby create a starting position 42 ( Fig. 11) of the second subcomponent 18 relative to the first subcomponent 16 without releasing 110 the second subcomponent 18, as described in more detail below. Similarly, the first robot arm 30 is configured to align the first plurality of guide holes 28 adjacent to the second plurality of guide holes 128 to thereby establish the home position 42 without releasing 110 the first subcomponent 16, as described in more detail below.

[0017] When considering the Fig. 2A and Fig. 2B, it can be seen that the component assembly system 14 also includes a robotic connection arm 44 which serves to form a connection 46 ( Fig. 2A and Fig. 2B) between the first subcomponent 16 and the second subcomponent 18. The robot connecting arm 44 contains a connecting device 48 that is designed to connect two subcomponents 16, 18 to one another. For example, the robot connecting arm 44 can be a welding robot arm that serves to create a weld between the first subcomponent 16 and the second subcomponent 18, wherein the connecting device 48 can be an arc welder. Alternatively, the robot connecting arm 44 can be a robot crimping arm that serves to create a crimp between the first subcomponent 16 and the second subcomponent 18, wherein the connecting tool 48 can be a plurality of rollers.Likewise, the robotic joining arm 44 may be any other suitable robotic arm, such as a robotic gluing arm, a robotic riveting arm, and the like, and the joining tool 48 may include any suitable elements for attaching the second subcomponent 18 to the first subcomponent 16. In one embodiment, the robotic joining arm 44 is a six-axis robotic articulated welding arm used to weld the first subcomponent 16 and the second subcomponent 18 together.

[0018] When considering the Fig. 2B and 3-5, it can be seen that the component assembly system 14 may include a fixture 50 that serves to support the first subcomponent 16. As described in more detail below, the fixture 50 may serve to support the first subcomponent 16 without compromising the structure or integrity of the first subcomponent 16. That is, regardless of whether the first subcomponent 16 defines existing fasteners or pilot holes, the fixture 50 may support the first subcomponent 16 during the manufacturing process and may provide precise alignment of the first subcomponent 16 with the second subcomponent 18 during material handling and / or assembly operations, such as during welding.

[0019] As from Fig. 2B, the holding device 50 may include a post 52 spaced apart from the first robot arm 30 and the second robot arm 130. The post 52 may be arranged, for example, on a central axis or in another position between the first robot arm 30 and the second robot arm 130. When considering the Fig. 5, it can be seen that the post 52 has a first end 54 and a second end 154 spaced from the first end 54. The post 52 may further include a longitudinal axis 56 extending between the first end 54 and the second end 154. In addition, the post 52 may also include a lateral axis 58 arranged perpendicular to the longitudinal axis 56. The post 52 may be configured for mounting in a production area or other area, such as a manufacturing facility, and thus may provide a rigid support member for the first subcomponent 16. The post 52 may thus be manufactured from a metal, plastic, or composite material depending on the desired rigidity and operating environment.

[0020] As further referred to Fig. 5, the holding device 50 may also include a first arm 60 attached to the post 52 at the first end 54. The first arm 60 may, for example, be a robotic arm that is stationary relative to the second end 154. That is, the first arm 60 may be attached to the first end 54 so that it does not extend along the longitudinal axis 56 or latitudinal axis 58 during operation of the holding device 50.

[0021] Furthermore, the holding device 50 optionally includes a first gripping element 62, which is attached to the first arm 60, e.g., at an end 64 of the first arm 60 remote from the center. The first gripping element 62 can be configured, as described in more detail below, during the manufacturing processes to support the first subcomponent 16. In particular, the first gripping element 62 can be configured to adapt to a shape of the first subcomponent 16, and thereby serve as a support element that can support the first subcomponent 16.

[0022] With reference to the Fig. 3 and Fig. 4, the first subcomponent 16, in one embodiment, may have a first surface 66 with a first contour 20, as well as a second surface 166 adjacent to the first surface 66 with a second contour 22 that differs from the first contour 20. In one embodiment, the first subcomponent 16 may be a tailgate or liftgate panel for a motor vehicle. Alternatively, the first subcomponent 16 may be a single part of an aircraft wing or an as yet unassembled seat. The holding device 50 can accommodate different shapes and contours 20, 22 and thus provide for flexible manufacturing processes. This means that the holding device 50 can be used for manufacturing processes that require successive first subcomponents 16 with different sizes and / or shapes.In other words, a holding device 50 can receive and support any number of first subcomponents 16, regardless of whether the first subcomponents 16 are similar in shape and size.

[0023] When considering the Fig. 8-10, it is noted that the first gripping member 62 may include a first cover 68 defining a first plurality of channels 70 therein. That is, the first gripping member 62 may define the first plurality of channels 70. The first gripping member 62 may further include a first plurality of pins 40. The first plurality of pins 40 may be an element of the component assembly system 14 that is arranged to support the first subcomponent 16 during manufacturing processes, such as assembly, inspection, placement, and the like.

[0024] How best to Fig. 10, for example, the first plurality of pins 40 may include nine pins 40 arranged in three rows 72 of three pins 40 each. This means that the first cover 68 may have a square cross-section, wherein the first plurality of pins 40 may be arranged in a square array of three rows 72 of three pins 40 each. During operation of the retaining device 50, the first plurality of pins 40 may each be adjacent to the first surface 66 of the first subcomponent 16.

[0025] More specifically, each of the first plurality of pins 40 is retractable into and displaceable from one of the respective channels of the first plurality of channels 70. In particular, each of the first plurality of pins 40 is individually retractable relative to at least one other pin of the first plurality of pins 40 in the respective one of the first plurality of channels 70 with respect to the at least one other one of the first plurality of pins 40. That is, each of the first plurality of pins 40 is individually retractable into and displaceable from the respective channel of the first plurality of channels 70. As such, and with reference to Fig. 4, it is therefore noted that during operation, each of the first plurality of pins 40 may extend from the first cover 68 by a different distance 74, 76.

[0026] For example, a first pin 78 of the first plurality of pins 40 may be adjacent to the first surface 66 and extend from the first cover 68 by a first distance 74, and a second pin 80 of the first plurality of pins 40 may be adjacent to the first surface 66 and extend from the first cover 68 by a second distance 76 that is greater than the first distance 74. Furthermore, each of the first plurality of pins 40 may be individually secured to the support position (at 82 in Fig. 4 generally shown), whereby the pin 40 comes into contact with the first subcomponent 16. Therefore, the first plurality of pins 40 can each actuate separately, ie, extend from or retract into the respective channel of the first plurality of channels 70, in order to adapt to a shape of the first subcomponent 16 and to form an exact contour 20, 22 ( Fig. 3) to support the first subcomponent 16.

[0027] Looking again at the Fig. 8 and Fig. 9, the first cover 68 includes a first actuation system 84 operable to translate the first plurality of pins 40 into and out of the first plurality of channels 70. The first actuation system 84 may receive an actuation signal (not shown), such as an electronic or thermal activation signal, which may mechanically actuate the first plurality of pins 40. In one embodiment, the first cover 68 may define a plurality of openings, such as a first inlet 86 and a first outlet 88, each operable to receive an actuating fluid, such as air, water, or oil. The first actuation system 84 may further include a plurality of seals 90 operable to maintain pneumatic pressure within the first cover 68. In one embodiment, the air may actuateeach of the first plurality of pins 40 individually from a first position in which the first plurality of pins 40 are within the first plurality of channels 70 to the support position 82 (. Fig. 4) is retracted, in which each of the first plurality of pins 40 is extended to abut the first subcomponent 16 according to a shape or contour 20, 22 of the first subcomponent 16. It should be noted that the support position 82 for one of the pins of the first plurality of pins 40 may correspond to the first distance 74 ( Fig. 4), while the support position 82 for another pin of the first plurality of pins 40 may correspond to the second distance 76 ( Fig. 4). This means that the support position 82 for a specific pin 40 can be determined by the contour 20, 22 of the first subcomponent 16.

[0028] As a non-limiting embodiment, the first plurality of pins 40 may initially be retracted into the first plurality of channels 70 in preparation for receiving the first subcomponent 16. Thereafter, the first subcomponent 16 may be spaced apart from the first plurality of pins 40. Air may then enter the first inlet 86 at a controlled flow rate such that each of the first plurality of pins 40 extends the same distance from the respective channel of the first plurality of channels 70 toward the first subcomponent 16. Thereafter, the first subcomponent 16 may translate toward the first cover 68, eventually becoming adjacent to the first plurality of pins 40. Once each of the first plurality of pins 40 is adjacent to the first surface 66 of the first subcomponent 16,touches the same, one or more pins of the first plurality of pins 40 are slightly retracted into the respective channel of the first plurality of channels 70 in order to thereby adapt the contour 20, 22 of the first subcomponent 16 and to support the first subcomponent 16 accordingly with a controlled force during the manufacturing process, such as during welding. Importantly, if the first subcomponent 16 is removed at this time, the first plurality of pins 40 would again extend from the first cover 68 by the same distance. After the manufacturing process is completed, the first subcomponent 16 may shift away from the first cover 68 so that the first plurality of pins 40 are no longer connected to the first.

[0029] Subcomponent 16 is adjacent and the air flows out of the first cover 68, if necessary, through the first outlet 88, so that the first plurality of pins 40 are retracted into the first plurality of channels 70. Subsequently, the subsequent first subcomponent 16 of the manufacturing process is ready to move into a position opposite the first arm 60, so that the holding device 50 is in turn ready to receive the subsequent first subcomponent 16.

[0030] Looking again at the Fig. 5, it can be seen that the holding device 50 may also include a second arm 160 attached to the post 52 between the first end 54 and the second end 154. The second arm 160 may, for example, be a robotic arm that is displaceable along the post 52 relative to the first arm 60 along the longitudinal axis 56. That is, the second arm 160 can be displaced toward and away from the first end 54 and may extend along the longitudinal axis 56 and / or the width axis 58 during operation of the holding device 50. More specifically, the holding device 50 may include a rail (not shown) on which the second arm 160 moves along the longitudinal axis 56 and / or the width axis 58. In contrast to the first arm 60, which can be stationary relative to the stand 52, the second arm 160 is therefore displaceable both along the longitudinal axis 56 and along the width axis 58.

[0031] Furthermore, the holding device 50 optionally includes a second gripping element 162, which is attached to the second arm 160, e.g., at an end 164 of the second arm 160 remote from the center. The second gripping element 162 can also be configured, as described in more detail below, during the manufacturing processes to support the first subcomponent 16. In particular, the second gripping element 162 can be configured to adapt to a shape of the first subcomponent 16 and thereby serve as a support element that can support the first subcomponent 16.

[0032] When considering the Fig. 8-10, it is noted that the second gripping member 162 may include a second cover 168 defining a second plurality of channels 170 therein. That is, the second gripping member 162 may define the second plurality of channels 170. Since the second arm 160 may translate along the width axis 58 ( Fig. 5), while the first arm 60 is stationary relative to the post 52 along the width axis 58, the first cover 68 can be spaced from the longitudinal axis 56 by a fixed distance 92. However, the second cover 168 can be spaced from the longitudinal axis 56 by a support distance 94 along the width axis 58. The support distance 94 can be less than the fixed distance 92. Alternatively, the support distance 94 can be greater than or equal to the fixed distance 92. The holding device 50 and the component assembly system 14 are therefore adaptable for first subcomponents 16 of different sizes and shapes and can enable flexible and cost-effective manufacturing.

[0033] Additionally, the second gripping element 162 may include a second plurality of pins 140. The second plurality of pins 140 may be an element of the component assembly system 14, which may be arranged to support the first subcomponent 16 during manufacturing processes, such as assembly, inspection, placement, and the like.

[0034] The second plurality of pins 140 includes, as shown Fig. 10, for example, nine pins arranged 140 in three rows 72 of three pins 140 each. This means that the second cover 168 may have a square cross-section, and the second plurality of pins 140 may be arranged in a square array of three rows 72 of three pins 140 each. During operation of the holding device 50, each of the second plurality of pins 140 may be adjacent to the second surface 166 of the first subcomponent 16.

[0035] More specifically, each of the plurality of pins 140 is optionally retractable into and displaceable from the respective channel 170 of the second plurality of channels. Each of the second plurality of pins 140 is optionally individually retractable into the respective channel of the second plurality of channels 170 relative to at least one other pin of the second plurality of pins 140. That is, each of the second plurality of pins 140 is optionally individually retractable into and displaceable from the respective channel of the second plurality of channels 170. Therefore, each of the second plurality of pins 140 can extend from the second cover 168 by a different distance 174, 176.

[0036] How best in Fig. 3, for example, a first pin 178 of the second plurality of pins 140 may be adjacent to the second surface 166 and extend from the second cover 168 by a third distance 174, and a second pin 180 of the second plurality of pins 140 may be adjacent to the second surface 166 and extend from the second cover 168 by a fourth distance 176 that is greater than the third distance 174. In addition, each of the second plurality of pins 140 may be extended from the support position (at 82 in Fig. 4), whereby the pin 140 comes into contact with the first subcomponent 16. Therefore, each of the second plurality of pins 140 is optionally individually actuated, ie, extended from or retracted into the respective channel of the second plurality of channels 170, in order to adapt to a shape of the first subcomponent 16 and to support a precise contour 20, 22 of the first subcomponent 16.

[0037] Looking again at the Fig. 8 and Fig. 9, it can be seen that the second cover 168 includes a second actuation system 184 that serves to translate the second plurality of pins 140 into and out of the second plurality of channels 170. The second actuation system 184 may receive an actuation signal (not shown), such as an electronic or thermal activation signal, that may mechanically actuate the second plurality of pins 140. In one embodiment, the second cover 168 may define a plurality of openings, such as a second inlet 186 and a second outlet 188, each for receiving an actuating fluid, such as air, water, or oil. The second actuation system 184 may further include a plurality of seals 90 that serve to maintain pneumatic pressure within the second cover 168. In one embodiment, the air may actuateeach of the first plurality of pins 140 individually from a first position in which each of the first plurality of pins 140 is within the first plurality of channels 170 to the support position 82 (. Fig. 4) is retracted, in which each of the first plurality of pins 140 is extended to abut the first subcomponent 16 according to a shape or contour 20, 22 of the first subcomponent 16. It should be noted that the support position 82 for one of the pins of the second plurality of pins 140 may correspond to the third distance 174, while the support position 82 for another pin of the second plurality of pins 140 may correspond to the fourth distance 176. This means that the support position 82 for a particular pin 140 may be determined by the contour 20, 22 of the first subcomponent 16.

[0038] As an exemplary embodiment, initially, in preparation for receiving the first subcomponent 16 during operation, the second plurality of pins 140 may be retracted into the second plurality of channels 170. Thereafter, the first subcomponent 16 may be spaced from the second plurality of pins 140. Air may then enter the second inlet 186 at a controlled flow rate such that each of the second plurality of pins 140 extends the same distance from the respective channel of the second plurality of channels 170 toward the first subcomponent 16. Thereafter, the first subcomponent 16 may translate toward the second cover 168, eventually becoming adjacent to the second plurality of pins 140. Once each of the second plurality of pins 140 is adjacent to the surface 66, 166 of the first subcomponent 16,touches the same, one or more pins of the second plurality of pins 140 are slightly retracted into the respective channel of the second plurality of channels 170 in order to thereby adapt the contour 20, 22 of the first subcomponent 16 and to support the first subcomponent 16 accordingly with a controlled force during the manufacturing process, such as during welding. It is important to note that if the first subcomponent 16 is removed at this time, the second plurality of pins 140 would again extend from the second cover 168 by the same distance. After the manufacturing process is completed, the first subcomponent 16 may shift away from the second cover 168 so that the second plurality of pins 140 are no longer adjacent to the first subcomponent 16 and the air may be evacuated from the second cover 168.through the second outlet 188, so that the second plurality of pins 140 are retracted into the second plurality of channels 170. Subsequently, the subsequent first subcomponent 16 of the manufacturing process is ready to move into a position opposite the second arm 160, so that the holding device 50 is in turn ready to receive the subsequent first subcomponent 16.

[0039] It should also be noted that the fixture 50 and the component assembly system 14 may include more than two gripping elements 62, 162 and more than two rows of pins 40, 140. For example, the fixture 50 and the component assembly system 14 may include three, four, five, or more gripping elements 62, 162 and three, four, five, or more rows of pins 40, 140. Therefore, the fixture 50 and the component assembly system 14 may include more than two arms 60, 160, including three, four, five, or more arms 60, 160. Furthermore, during operation, more than one of the arms 60, 160 is movable along both the longitudinal axis 56 and the lateral axis 58. As such, the fixture 50 and the component assembly system 14 can provide user-defined and precise positioning and placement of the subcomponents 16, 18.

[0040] Therefore, the fixture 50 and the component assembly system 14 may be particularly suitable for manufacturing steps that span variously sized first subcomponents 16. That is, the fixture 50 and the component assembly system 14 can provide a conforming, flexible tool that transmits a controlled support force to the first subcomponent 16. Furthermore, since some first subcomponents 16 may be too wide for a two-sided clamp, the fixture 50 can provide one-sided support during manufacturing processes.

[0041] Looking again at the Fig. 1, as described above, the method 10 may also include, after grasping 24, positioning 38 the first plurality of pins 40 in alignment with the first plurality of guide holes 28. Likewise, the method 10 may include arranging 96 the second plurality of pins 140 in alignment with the second plurality of guide holes 128. That is, in the method 10, the first robotic arm 30 may pick up and grasp the first subcomponent 16 and then translate the first subcomponent 16 toward the fixture 50 such that the first plurality of guide holes 28 are aligned with the first plurality of pins 40 and the second plurality of guide holes 128 are aligned with the second plurality of pins 140.

[0042] In parallel with positioning 38 and arrangement 96, the method 10 may include retracting 98 each of the first plurality of pins 40 into the respective channel of the first plurality of channels 70, as well as retracting 98 each of the second plurality of pins 140 into the respective channel of the second plurality of channels 170. This means that each of the first plurality of pins 40, as well as each of the second plurality of pins 140 can be retracted into the respective channel of the first plurality of channels 70 and the second plurality of channels 170, so that the pins 40, 140 do not press against the first subcomponent 16 and do not come into contact with it in the first place. Rather, the pins 40, 140 are aligned with both the first plurality of guide bores 28 and the second plurality of guide bores 128 such that the pins 40, 140 are ready to move out of the respective one of the plurality of channels 70, 170.

[0043] In addition to or parallel to the positioning 38 and arrangement 96, the second robot arm 130, as set forth above, can pick up or grasp the second subcomponent 18. Following the grasping 36, the method 10 includes the alignment 100 of at least one of the plurality of guide bores 28 adjacent to at least one of the second plurality of guide bores 128 to thereby establish the starting position 42 ( Fig. 11) of the second subcomponent 18 relative to the first subcomponent 16 without releasing 110 the first subcomponent 16 from the first gripping element 26 and without releasing 110 the second subcomponent 18 from the second gripping element 126. This means that the second robot arm 130 can place and align the second subcomponent 18 relative to the first subcomponent 16 by aligning 100 the second plurality of guide holes 128 on and adjacent to the first plurality of guide holes 28 in the free space. The second robot arm 130 can place and align the second subcomponent 18 without releasing 110 or letting go of the second subcomponent 18, for example, in a clamping device for tools or workpieces (not shown).Likewise, by aligning 100 the first plurality of guide holes 28 on and adjacent to the second plurality of guide holes 128 in the free space, the first robot arm 30 can place and align the first subcomponent 16 relative to the second subcomponent 18 without releasing 110 the first subcomponent 16, for example, into a clamping device for tools or workpieces (not shown).

[0044] In an exemplary embodiment, the first robot arm 30 and / or the second robot arm 130 may be equipped with an optical recognition system (not shown) used to detect the position of the objects. Therefore, the second robot arm 130 may visually scan the first subcomponent 16 to locate the first plurality of guide holes 28 and subsequently align the second plurality of guide holes 128 defined by the second subcomponent 18 with the first plurality of guide holes 28. Furthermore, the second robot arm 130 may be configured, as described in more detail below, to relocate or realign the second subcomponent 18 relative to the first subcomponent 16.

[0045] Looking again at the Fig. 1, Fig. 2A and Fig. 2B, it can be seen that the process 10, following the alignment 100, also includes the preparation 102 of the compound 46 ( Fig. 2A and Fig. 2B) between the first subcomponent 16 and the second subcomponent 18 with the joining tool 48 attached to the robot joining arm 44, thereby assembling the component 12. This forming 102 includes, for example, welding the second subcomponent 18 to the first subcomponent 16 to create a welded connection between the first and second subcomponents 16, 18. Alternatively, the connection creation 102 includes crimping or gluing the first subcomponent 16 and second subcomponent 18 together to create a crimped or adhesive connection.

[0046] However, before the connection is established 102, the method 10 may also include a displacement 104 of the second subcomponent 18 relative to the first subcomponent 16 in order to thereby establish the starting position 42 ( Fig. 11) a final position 106 ( Fig. 2A). This means that the second robot arm 130 can be configured to detect a misalignment between the first plurality of guide holes 28 and the second plurality of guide holes 128 and thus slightly displace the second subcomponent 18 to adjust the second subcomponent 18 to the end position 106. For example, the second robot arm 130 can be configured to adjust the second subcomponent 18 to the end position 106 according to a comparison between the starting position 42 ( Fig. 11) and the desired end position 106, make all necessary distance adjustments to the second subcomponent 18. It is important that the second robot arm 130 can move the second subcomponent 18 in free space without the aid of the holding device 50 and / or the first plurality of pins 40 or the second plurality of pins 140.

[0047] In contrast, the first robot arm 30 can be configured to detect a misalignment between the first plurality of guide holes 28 and the second plurality of guide holes 128 and thus to move the first subcomponent 16 to place the first subcomponent 16 at the same end position 106 ( Fig. 2A). This means that the first robot arm 30 can be adjusted according to a comparison between the starting position 42 ( Fig. 11) and the desired end position 106, make all necessary distance adjustments to the first subcomponent 16. It is important that the first robot arm 30 can move the first subcomponent 16 in free space without the aid of the holding device 50 and / or the first plurality of pins 40 or the second plurality of pins 140.

[0048] Alternatively or additionally, both the first robot arm 30 and the second robot arm 130 can cooperate to identify and detect an incorrect alignment between the first plurality of guide bores 28 and the second plurality of guide bores 128, wherein both the first robot arm 30 and the second robot arm 130 can move the first subcomponent 16 and the second subcomponent 18, respectively, in order to adjust both the first subcomponent 16 and the second subcomponent 18 with respect to one another to the end position 106. This means that the first robot arm 30, without the aid of the holding device 50 and / or the first plurality of pins 40 and the second plurality of pins 140, can move the first subcomponent 16 in free space, while the second robot arm 130 also moves the second subcomponent 18 in free space.The component assembly system 14 therefore enables robot-to-robot alignment of subcomponents 16, 18 without having to configure physical tools to support the subcomponents 16, 18. Thus, the method 10 and the component assembly system 14 may potentially save floor space and enable a compact design of manufacturing systems.

[0049] Further, following positioning 38 and arrangement 96, the method 10 optionally includes moving 108 each of the first plurality of pins 40 out of the corresponding one of the first plurality of channels 70, and moving 108 each of the second plurality of pins 140 out of the corresponding one of the second plurality of channels 170, such that each of the first plurality of pins 40, as well as each of the second plurality of pins 140, comes into contact with the first subcomponent 16 to cause the fixture 50 and the second robot arm 130 to clamp the first subcomponent 16 and the second subcomponent 18 together.

[0050] This means that the first plurality of pins 40 may extend from the first plurality of channels 70 and come into contact with the first surface 66, and each of the second plurality of pins 140 may extend from the second plurality of channels 170 and come into contact with the second surface 166, thereby pressing against and supporting the first subcomponent 16, while the second robot arm 130 presses the second subcomponent 18 against the first subcomponent 16. Said displacement 108 may hold and secure the relative position of the first and second subcomponents 16, 18. This means that the holding device 50 may serve as a backstop or support and provide a one-sided connection of the first and second subcomponents 16, 18. In other words, the robot connecting arm 44 may form the connection 46 ( Fig. 2B) between the first and second subcomponents 16, 18 without holding the subcomponents 16, 18 together. Rather, the robotic connecting arm 44 can position itself, apply welding energy, and quickly join the first and second subcomponents 16, 18 together without first clamping the two subcomponents 16, 18 together. This can increase assembly speed, processing volume, and manufacturing flexibility, and reduce manufacturing costs and downtime.

[0051] Looking again at the Fig. 1, the method 10, following the connection creation 102, also includes, if necessary, the release 110 of the second subcomponent 18 from the second gripping element 126, as well as the gripping 36 of a further second subcomponent 18 with the second gripping element 126. This means that as soon as the robot connection arm 44 creates the connection 46 between the first and second subcomponents 16, 18 and, for example, forms a weld seam between the two subcomponents 16, 18, the second subcomponent 18 is initially fastened to the first subcomponent 16 and no longer requires any additional clamping or support. Therefore, the robot connection arm 44 forms, if necessary, further connections 46 between the first and second subcomponents 16, 18, while the second robot arm 130 grips a further second subcomponent 18 with the second gripping element 126. The said release 110 therefore also increases the assembly speed and processing quantity of the manufacturing processes.

[0052] Therefore, the method 10 and the component assembly system 14 may be particularly suitable for manufacturing steps that continuously span components 12 of various sizes and shapes. More specifically, the method 10 and component assembly system 14 provide a conforming, flexible tool that imparts a controlled support force to the component 12 during the manufacturing processes. The method 10 and component assembly system 14 may be particularly suitable for components 12 that have complex shapes or contours 20, 22 ( Fig.3). For example, the method 10, as well as the component assembly system 14, may enable flexible manufacturing processes that can accommodate different sized and shaped tailgates and liftgates without having to change tools, which may prove particularly useful during a model change. This means that the component assembly system 14 can simply be electronically reprogrammed during a model change, rather than requiring a physical changeover. Therefore, the component assembly system 14 does not allow for hardware changes, only software changes, whenever a size or shape of the component 12 changes.

[0053] Furthermore, the method 10 and the component assembly system 14 may be suitable for those manufacturing operations and environments that require precise positioning and placement of workpieces, since the method 10 may include the alignment 100 and translation 104 of the first and second subcomponents 16, 18. Furthermore, since some components 12 may be too wide or contoured for a two-sided fixture, the method 10 and the component assembly system 14 provide one-sided support during the manufacturing processes.

Claims

[1] Component assembly system comprising: a first robot arm (30); a first subcomponent (16) defining a first plurality of guide bores (28); a first gripping element (26) attached to the first robot arm (30) for gripping the first subcomponent (16); a second robot arm (130) which is displaceable in the direction of the first robot arm (30); a second subcomponent (18) defining a second plurality of guide bores (128); a second gripping element (126) attached to the second robot arm (130) for gripping the second subcomponent (18); wherein the second robot arm (130) serves to align the first plurality of guide holes (28) adjacent the second plurality of guide holes (128) to thereby establish a starting position of the second subcomponent (18) relative to the first subcomponent (16) without releasing the second subcomponent (18) from the second gripping element (126); wherein the first robot arm (30) serves to align the first plurality of guide holes (28) adjacent the second plurality of guide holes (128) to thereby establish the home position without releasing the first subcomponent (16) from the first gripping element (26); a robot connection arm which serves to establish a connection between the first and the second subcomponent (16, 18), and a holding device (50) for supporting the first subcomponent (16) contains the following individual parts: a stand (52) spaced from the first robot arm (30) and second robot arm (130) having the following properties: a first end (54); a second end (154) spaced from the first end (54); and a longitudinal axis (56) extending between the first end (54) and the second end (154); a first arm (60) attached to the stand (52) at the first end (54), the first arm (60) being stationary relative to the second end (154); a first gripping element (62) attached to the first arm (60) and having the following properties: a first cover (68) defining a first plurality of channels (70) contained therein; and a first plurality of pins (40), each of the first plurality of pins (40) being retractable into and slidable from the corresponding one of the first plurality of channels (70); wherein each of the first plurality of pins (40) is initially retracted into the corresponding one of the first plurality of channels (70) in preparation for receiving the first subcomponent (16) when the first subcomponent (16) is spaced from the first plurality of pins (40); a second arm (160) attached to the post (52) between the first and second ends (54, 154), the second arm being displaceable along the post (52) relative to the first arm (60) along the longitudinal axis (56); and a second gripping element (162) attached to the second arm (160) having the following properties: a second cover (168) defining a second plurality of channels (170) therein; and a second plurality of pins (140), each of the second plurality of pins (140) being retractable into and slidable out of a corresponding one of the second plurality of channels (170); wherein each of the second plurality of pins (140) is initially retracted into the corresponding one of the second plurality of channels (170) in preparation for receiving the first subcomponent (16) when the first subcomponent (16) is spaced from the second plurality of pins (140). [2] The component mounting system of claim 1, wherein the post (52) further includes a width axis (58) disposed perpendicular to the longitudinal axis (56), and further wherein the second arm (160) is slidable along the width axis (58). [3] The component mounting system of claim 2, wherein each of the first plurality of pins (40) is independently retractable into the respective one of the first plurality of channels (70) in relation to the at least one other of the first plurality of pins (40).

Images