ROBOT SYSTEM FOR SHAPING A MOLDABLE WORKPIECE

Abstract

Robot system (100) for forming a formable workpiece (106), the robot system (100) comprising: a robot (102) configured to guide the workpiece (106) through a machine (109); an end effector (108) configured to be attached to the robot (102) and configured to grip and release the workpiece (106), the end effector (108) being adjustable to a variety of different configurations; a setting module (110) configured to determine a change in the workpiece (106) from (a) a first shape of the workpiece (106) before the workpiece (106) passes through the machine (109) to (b) a second shape of the workpiece (106) after the workpiece (106) passes through the machine (109); and a control module (104) configured to adjust a current configuration of the end effector (108) to a second configuration based on the change of the workpiece (106) from (a) the first shape to (b) the second shape.

Description

[0001] The present disclosure relates to vehicle manufacturing and, more particularly, to a robot system for free-forming a workpiece of a vehicle.

[0002] Various types of materials are used to manufacture vehicles, such as aluminum, steel, plastic, etc. Some vehicle components are formed from sheet metal. Examples of such vehicle components include frames, doors, hoods, roofs, trunk lids, etc.

[0003] In a vehicle manufacturing facility, robots and other types of forming machines can assist in forming components.

[0004] DE 10 2021 111 279 A1 discloses a gripping system for holding a workpiece, comprising a shape-adjusting tool consisting of two arms that can be pivoted relative to each other via a joint, a clamping structure consisting of several layers that form a pressurizable interior, and a pressure system with a pump coupled to the interior. To hold the workpiece, the two arms of the shape-adjusting tool are pivoted toward the workpiece, and then the interior of the clamping structure is pressurized with compressed air to impart rigidity to the clamping structure and hold the workpiece.

[0005] Further prior art is described in DE 10 2016 224 377 A1, DE 20 2014 103 132 U1, DE 10 2013 202 571 B4, DE 27 42 226 A1 and AT 521 039 B1.

[0006] The object of the invention is to provide a robot system for forming a formable workpiece, with which it is possible to grip a workpiece at a suitable location for subsequent post-processing, and which enables a safe and damage-free gripping of a subsequently formed workpiece by the robot system.

[0007] The object is solved by the subject matter of claim 1. Advantageous developments of the invention are described in the subclaims.

[0008] A robotic system for reshaping a deformable workpiece includes a robot, an end effector, an adjustment module, and a control module. The robot is configured to pass the workpiece through a machine. The end effector is configured to be attached to the robot and is configured to grip and release the workpiece. The end effector is adjustable to a plurality of different configurations. The adjustment module is configured to determine a change of the workpiece from (a) a first form of the workpiece before passing the workpiece through the machine to (b) a second form of the workpiece after passing the workpiece through the machine. The control module is configured to adjust a current configuration of the end effector to a second configuration based on the change of the workpiece from (a) the first form to (b) the second form.

[0009] In one example, a camera is configured to capture (a) a first image of the workpiece before the workpiece passes through the machine and (b) a second image of the workpiece after the workpiece passes through the machine. The setup module is configured to determine the first shape of the workpiece based on the first image and the second shape of the workpiece based on the second image.

[0010] In one example, at least one camera is configured to capture an image of the workpiece as the workpiece is moved through the machine. The setting module is configured to determine a current shape of the workpiece based on the image. The control module is configured to adjust the current configuration of the end effector based on the current shape of the workpiece and as the workpiece moves through the machine.

[0011] In one example, the end effector includes a force sensor configured to measure (a) a first force applied by the end effector to the workpiece before the workpiece passes through the machine, and (b) a second force applied by the end effector to the workpiece after the workpiece passes through the machine. The adjustment module is configured to determine the first shape based on the first force and the second shape based on the second force.

[0012] In one example, the end effector includes a force sensor configured to measure a force exerted by the end effector on the workpiece as the workpiece passes through the machine. The adjustment module is configured to determine a current shape of the workpiece based on the force. The control module is configured to adjust the current configuration of the end effector based on the current shape of the workpiece as the workpiece passes through the machine.

[0013] In one example, the end effector includes a support portion and a fixture attached to the support portion and configured to grip and release the workpiece. The control module is configured to adjust the current configuration of the end effector by adjusting the fixture.

[0014] In one example, the control module is configured to move the fastening device in at least one of the X, Y, and Z directions, where the X, Y, and Z directions are perpendicular to each other.

[0015] In one example, the control module is configured to rotate the fixture about at least an X-axis, a Y-axis, and a Z-axis, wherein the X-, Y-, and Z-axes are perpendicular to each other.

[0016] In one example, the fastening device comprises a first fastening device movable relative to the support portion of the end effector, and the end effector further comprises a second fastening device attached to the support portion.

[0017] In one example, the machine is at least one of an English wheel or a jackhammer.

[0018] In one example, the robot system further comprises a second robot and a second end effector. The second end effector is configured to be attached to the second robot and is configured to grip and release the workpiece. The end effector and the second end effector grip opposite ends of the workpiece.

[0019] An example of a robotic system for forming a formable workpiece includes a robot, an end effector, a camera, a first adjustment module, and a control module. The robot is configured to guide the workpiece through a machine. The end effector includes a support portion and a fixture attached to the support portion. The fixture is configured to grip and release the workpiece and is adjustable to a variety of configurations. The camera is configured to capture (a) a first image of the workpiece before the workpiece passes through the machine and (b) a second image of the workpiece after the workpiece passes through the machine.The first adjustment module is configured to determine a change of the workpiece from (a) a first shape before the workpiece passes through the machine to (b) a second shape of the workpiece after the workpiece passes through the machine using the first image and the second image. The control module is configured to adjust a current configuration of the fixture to a second configuration based on the change of the workpiece from (a) the first shape to (b) the second shape.

[0020] In one example, the end effector comprises a rail fixedly connected to the support portion, and the attachment device is movable along the rail.

[0021] In one example, the attachment device is a suction cup that is spring loaded.

[0022] In one example, the fixture includes a housing and a pair of fingers extending from the housing. The control module is configured to actuate the pair of fingers to grip and release the workpiece.

[0023] In one example, the control module is configured to actuate the clamping device to release the workpiece after the workpiece has passed through the machine and is configured to re-grip the workpiece prior to a subsequent pass of the workpiece through the machine.

[0024] In one example, the robot system further includes a second adjustment module. The end effector includes a force sensor configured to measure (a) a first force applied to the workpiece by the fixture before the workpiece passes through the machine and (b) a second force applied to the workpiece by the fixture after the workpiece passes through the machine. The second adjustment module is configured to determine the first shape based on the first force and the second shape based on the second force.

[0025] In one example, the second adjustment module is configured to determine a second change of the workpiece from (a) the first shape to (b) the second shape. The control module is configured to adjust the current configuration of the fixture based on at least one of the change and the second change to the workpiece.

[0026] In one example, the robot system further comprises a second robot and a second end effector. The second end effector is configured to be attached to the second robot and is configured to grip and release the workpiece. The end effector and the second end effector grip opposite ends of the workpiece.

[0027] A robotic system method for forming a formable workpiece is provided. The method includes acquiring a first image of a workpiece prior to passing the workpiece through a machine. The method includes determining a first shape of the workpiece prior to passing the workpiece through the machine based on the first image. The method includes passing the workpiece through the machine using an end effector. The method includes acquiring a second image of the workpiece after passing the workpiece through the machine. The method includes determining a second shape of the workpiece after passing the workpiece through the machine based on the second image. The method includes determining a change of the workpiece from (a) the first shape to (b) the second shape.The method includes adjusting a current configuration of the end effector to a second configuration based on the change of the workpiece from (a) the first shape to (b) the second shape.

[0028] The present disclosure will become more fully understood from the detailed description and the accompanying drawings, in which: Fig. 1 is a functional block diagram of an exemplary robot system; Fig. 2 is a perspective view of an exemplary robot and an exemplary end effector grasping an exemplary workpiece; Fig. 3 is a partial side view of the exemplary end effector gripping the workpiece when the workpiece is in a first shape and gripping the workpiece when the workpiece is in a second shape; Fig. 4 a plan view of an exemplary fastening device for the Fig. 2-3 shown end effector; Fig. 5 is a side view of another exemplary end effector gripping the workpiece; Fig. 6 is a partial perspective view of an exemplary fastening device for the Fig. 5 shown end effector; Fig. 7 a partial cross-sectional view of the Fig. 6 is an exemplary fastening device; Fig. 8 is a perspective view of an exemplary first robot attached to a first end effector and an exemplary second robot attached to a second end effector; and Fig. 9 is a flowchart illustrating an exemplary method for controlling an exemplary robot system.

[0029] Reference numbers may be used repeatedly in the drawings to identify similar and / or identical elements.

[0030] Punching machines can be used to punch and form material into vehicle components for vehicle manufacturing.

[0031] This application concerns a robot system for freeforming workpieces for vehicle manufacturing. One or more robots can each be attached to an end effector. The end effector can be adjusted to a variety of configurations. The end effectors are configured to grip and release a workpiece.

[0032] The workpiece is formable into a variety of shapes. The robots may pass the workpiece through a machine (e.g., a jackhammer, an English wheel, etc.) one or more times to change the shape / forming of the workpiece. For example, the workpiece is passed from a first shape before passing through the machine to a second shape after passing through the machine. The workpiece is repeatedly passed through the machine until the workpiece is formed into a target shape. In one example, the target shape of the workpiece may be the shape of a Class A automotive panel of a low-production vehicle. However, the target shape of the workpiece may be the shape of a different component and / or vehicle type. The present application is also applicable to non-automotive components.

[0033] As the workpiece shape changes from the first shape to the second shape, the end effector configuration may not be suitable for gripping the second shape of the workpiece. For example, the end effector may not be able to grip the workpiece without inadvertently deforming it. Furthermore, a location where the end effector grips the workpiece may compromise an area of ​​the workpiece that is intended to be formed during a subsequent pass through the machine.

[0034] Given the above, the robot system detects the shape change of the workpiece and automatically adjusts the configuration of the end effector accordingly.

[0035] Fig. 1 is a functional block diagram of an exemplary robotic system 100. The robotic system 100 may be located in a vehicle manufacturing facility of a vehicle original equipment manufacturer (OEM). The robotic system 100 may include one or more robots 102 and a control module 104 configured to control the movement and operation of the one or more robots 102.

[0036] The robots 102 are configured to grasp and move a workpiece 106 within the vehicle manufacturing facility. Each robot 102 can be attached to an end effector 108. The end effector 108 is configured to grasp and release the workpiece 106. While grasping the workpiece 106, the robots 102 are configured to pass the workpiece 106 through a machine 109 one or more times to form the workpiece 106 into a target shape.

[0037] The machine 109 can be a lathe, a pneumatic hammer, or another machine type. The machine 109 can physically change the shape / form of the workpiece 106 when the workpiece 106 is within the machine 109. For example, the workpiece 106 can be in a first form before passing through (a section or the entire workpiece 106) the machine 109 and in a second form after passing through the machine 109. The form of the workpiece 106 can include a shaping of the workpiece 106, a size of the workpiece 106, and / or one or more other physical properties of the workpiece 106. In one example, the first form can be the form of a flat sheet and the second form can be the non-flat form of a desired vehicle component.

[0038] The robot system 100 may include a first adjustment module 110, a second adjustment module 112, or both the first and second adjustment modules 110, 112.

[0039] The first adjustment module 110 is an image-based module. One or more cameras 114 are positioned within the vehicle manufacturing facility and configured to capture images of the workpiece 106. In one example, a first camera may be disposed on a first side of the workpiece 106 and a second camera may be disposed on a second side of the workpiece 106. The first and second cameras may be disposed opposite each other, perpendicular to each other, or in any other suitable position relative to each other.

[0040] The cameras 114 are configured to capture images of the workpiece 106 when the workpiece 106 is within the field of view of the cameras 114. The cameras 114 are configured to capture images of the workpiece 106 from a first point in time before the workpiece 106 passes through the machine 109 to a second point in time after the workpiece 106 passes through the machine 109. The cameras 114 can transmit the images, either wired or wirelessly, to the first adjustment module 110, either during or after the images are captured.

[0041] The first adjustment module 110 determines the current shape of the workpiece 106 based on one or more current (e.g., last received) images from the cameras 114. The first adjustment module 110 can transmit the current shape of the workpiece 106, either wired or wirelessly, to the control module 104.

[0042] Additionally, the cameras 114 are configured to capture first images before the workpiece 106 passes through the machine 109 and second images after the workpiece 106 has passed through the machine 109. The first setting module 110 is configured to determine the first shape of the workpiece 106 based on at least one of the first images and to determine the second shape of the workpiece 106 based on at least one of the second images.

[0043] The first adjustment module 110 is configured to determine a first change of the workpiece 106 from the first shape (e.g., before the workpiece 106 passes through the machine 109) to the second shape (e.g., after the workpiece 106 passes through the machine 109) based on at least one of the first images and at least one of the second images. The first adjustment module 110 can transmit the first change of the workpiece 106 to the control module 104 wired or wirelessly.

[0044] In one example, one or more identifiers are arranged on the workpiece 106. Examples of identifiers include reference points (e.g., reflective), QR codes, markings, or other suitable types of visual identifiers. The cameras 114 are configured to capture images of the identifiers on the workpiece 106. Using at least one of the first images, the first adjustment module 110 is configured to determine a first one or more locations of the identifiers or the first shape of the workpiece 106. Using at least one of the second images, the first adjustment module 110 is configured to determine a second one or more locations of the identifiers or the second shape of the workpiece 106. The first adjustment module 110 is configured to perform the first change of the workpiece 106 from the first shape to the second shape based on a change in the first one or more locations orthe second one or more digits of the identifiers.

[0045] In another example, the workpiece 106 may be painted and have a pattern in the paint. Using at least one of the first images, the first adjustment module 110 is configured to determine a first pattern of the paint and determine the first shape of the workpiece 106 based on the first pattern of the paint. Using at least one of the second images, the first adjustment module 110 is configured to determine a second pattern of the paint and determine the second shape of the workpiece 106 based on the second pattern of the paint. The first adjustment module 110 is configured to determine the first change in the workpiece 106 based on a change between the first and second patterns.

[0046] The second adjustment module 112 is a force-based module. One or more force sensors 120 are disposed on the end effector 108. More specifically, the end effector 108 includes at least one fixture 122 configured to grip and hold the workpiece 106 while the workpiece 106 is guided through the machine 109. The at least one fixture 122 exerts a force on the workpiece 106 to grip and hold the workpiece 106. The force sensors 120 may be disposed on a contact surface of the at least one fixture 122. The force sensors 120 are configured to measure the force on the fixture 122 (e.g., the contact surface) between the fixture 122 and the workpiece 106.In one example, the force sensors 120 are configured to measure the force on the fastener 122 by measuring an extensional stress of the fastener 122.

[0047] The force sensors 120 are configured to measure forces throughout the entire forming process, including the first time before the workpiece 106 passes through the machine 109 to the second time after the workpiece 106 has passed through the machine 109. The force sensors 120 can transmit the force measurements to the second adjustment module 112 wired or wirelessly during or after the force is measured.

[0048] The second adjustment module 112 is configured to determine the current shape of the workpiece 106 using at least one of the forces received from the force sensors 120. More specifically, the second adjustment module 112 is configured to determine a material strain in the workpiece 106 based on the at least one of the forces and to determine the current shape of the workpiece 106 based on the material strain. The second adjustment module 112 can transmit the current shape of the workpiece 106 to the control module 104 wired or wirelessly.

[0049] Additionally, the force sensors 120 are configured to detect first forces before the workpiece 106 passes through the machine 109 and second forces after the workpiece 106 has passed through the machine. The second adjustment module 112 is configured to determine the first shape of the workpiece 106 using at least one of the first forces (before passing through the machine 109) and the second shape of the workpiece 106 using at least one of the second forces (after passing through the machine 109).

[0050] The second adjustment module 112 is configured to determine a second change in the workpiece 106 based on a change between at least one of the first forces and at least one of the second forces. For example, a larger change in the forces may correspond to a greater deformation or elongation of the workpiece 106. A smaller change in the forces may correspond to a lesser deformation or elongation of the workpiece 106. The second adjustment module 112 may transmit the second change in the workpiece 106 to the control module 104 wired or wirelessly.

[0051] The control module 104 is configured to control the actuation and movement of the robots 102. Based on the second shape of the workpiece 106 (the shape of the workpiece 106 after passing through the machine 109), the control module 104 is configured to determine whether the workpiece 106 has changed to (or is in) the target shape. For example, the control module 104 may compare the second shape of the workpiece 106 to predetermined computer-aided design (CAD) models.

[0052] If the second shape of the workpiece 106 substantially conforms to the target shape, the forming of the workpiece 106 may be considered complete, and the workpiece 106 may not be passed through the machine 109 again. If the second shape of the workpiece 106 does not substantially conform to the target shape, the control module 104 is configured to control the robot(s) 102 and pass the workpiece 106 through the machine 109 one more time. Substantially conforms may mean "within one or more specified tolerances."If the second shape of the workpiece 106 does not substantially match the target shape, the control module 104 is configured to determine a path for advancing the workpiece 106 through the machine 109 and a location for the at least one fixture 122 for gripping the workpiece 106 based on at least one of the second shape of the workpiece 106, the first or second change in the workpiece 106, and the target shape of the workpiece 106. The path may include the angle at which the workpiece 106 is positioned, the speed at which the workpiece 106 is advanced through the machine 109, and / or one or more other parameters for advancing the workpiece 106 through the machine 109. The control module 104 controls the robot(s) 102 to advance the workpiece 106 through the machine 109 according to the determined parameter(s).

[0053] If the second shape of the workpiece 106 does not substantially match the target shape, the control module 104 is further configured to determine a configuration of the end effector 108 for passage through the machine 109. The control module 104 is configured to adjust the configuration of the end effector 108 during the passage of the workpiece 106 through the machine 109 based on the current shape of the workpiece 106. Furthermore, the control module 104 is configured to adjust the configuration of the end effector 108 after the workpiece 106 has passed through the machine 109 based on at least one of the first and second changes to the workpiece 106. Adjusting the configuration of the end effector 108 includes adjusting (e.g., a position and / or orientation) the at least one fixture 122 of the end effector 108.

[0054] For example, the first configuration may be a configuration of the end effector 108 when the workpiece 106 is in the first mold. The second configuration may be a configuration of the end effector 108 when the workpiece 106 is in the second mold.

[0055] Fig. 2 is a perspective view of an example robot 130 and an example end effector 132 grasping an example workpiece 134. Fig. 3 is a partial side view of the end effector 132 in a first configuration gripping the workpiece 134 while the workpiece 134 is in an exemplary first shape, and the end effector 132 in a second configuration gripping the workpiece 134 while the workpiece 134 is in an exemplary second shape.

[0056] As in Fig. As shown in FIG. 2, the exemplary robot 130 can include a base 136 and a robot arm 138. The base 136 can be positioned on a floor surface of the vehicle manufacturing plant or alternatively on a stand. The robot arm 138 extends between a first end 140 and a second end 142 that is opposite the first end. The first end 140 of the robot arm 138 can be attached to the base 136. In the illustrated example, the robot 130 can be a six-degree-of-freedom (DOF) robot. However, any suitable robot 130 can be used, e.g., a robot with 3 DOF or more.

[0057] As shown in Fig. FIG. 2, the second end 142 of the robot arm 138 can be attached to the end effector 132 and configured to move the end effector 132.

[0058] In some configurations, the second end 142 of the robot arm 138 can be separated from the end effector 132 and attached to a reconfiguration tool. The reconfiguration tool can be configured to adjust one or more components of the end effector 132 and can be separated from the reconfiguration tool after adjusting the end effector 132 to a target configuration. The reconfiguration tool can be a pneumatic torque wrench or other type of reconfiguration tool. Alternatively, the control module 104 can adjust the configuration of the end effector 132 by transmitting a command to the end effector 132 and without a reconfiguration tool.

[0059] The end effector 132 may include a connector 150 and a support portion 152. The connector 150 extends from the support portion 152 and may be attached to the second end 142 of the robot arm 138. The support portion 152 extends between a third end 156 and a fourth end 158 opposite the third end 156, and includes a first side 160 and a second side 162 opposite the first side 160. In the example shown, the connector 150 is arranged approximately perpendicular to the support portion 152 and extends from the first side 160 of the support portion 152. The connector 150 may be arranged equidistantly between the third and fourth ends 156, 158 of the support portion 152.However, the connector 150 may be arranged at any suitable angle relative to the support portion 152 and may be positioned in any suitable position between the third and fourth ends 156, 158 of the support portion 152.

[0060] In addition, the end effector 132 may include one or more attachment devices movably attached to the support portion 152. In the illustrated example, the one or more attachment devices include a first attachment device 164 and a second attachment device 166. The first and second attachment devices 164, 166 are disposed on the second side 162 of the support portion 152. The first attachment device 164 is disposed near the third end 156 of the base 136. The second attachment device 166 is disposed near the fourth end 158 of the base 136. However, the end effector 132 may also include a greater or lesser number of attachment devices.

[0061] The first and second fixtures 164, 166 are configured to grip and release the workpiece 134. In one example, the workpiece 134 may be preloaded during gripping of the workpiece 134. The first and second fixtures 164, 166 may grip the workpiece 134 before the workpiece 134 passes through the machine 109 and release the workpiece 134 after the workpiece 134 passes through the machine 109.

[0062] Additionally, the first and second fixtures 164, 166 may be actuated pneumatically or in another suitable manner to hold the workpiece 134. For example, the robot 130 may draw air from within the first and second fixtures 164, 166 to hold the workpiece 134 to the first and second fixtures 164, 166.

[0063] The configuration of the end effector 132 can be adjusted by adjusting at least one of the first attachment devices 164 and the second attachment devices 166 with respect to the support portion 152. In one example, the first attachment device 164 can be movable and the second attachment device 166 can be stationary. In another example, the second attachment device 166 can be movable and the first attachment device 164 can be stationary. In yet another example, both the first and second attachment devices 164, 166 can be movable.

[0064] The first and / or second fastening devices 164, 166 may be movable along an X-axis 170, a Y-axis 172, a Z-axis 174, or a combination thereof relative to the support portion 152 of the end effector 132. Additionally, the first and / or second fastening devices 164, 166 may be rotatable about the X-axis 170, the Y-axis 172, the Z-axis 174, or a combination thereof. For example, the first fastening device may be movable along the X- and Y-axis 170, 172 and rotatable about the X-, Y-, and Z-axes 170, 172, 174, and the second fastening device 166 may be stationary.

[0065] Movement along the X-axis 170 is represented by movement into and out of the support portion 152 of the end effector 132. Movement along the Y-axis 172 is represented by sliding movement along the support portion 152 of the end effector 132. More specifically, the first attachment device 164 may be slidable relative to the support portion 152 between the third end 156 of the support portion 152 and the second attachment device 166. The second attachment device 166 may be slidable relative to the support portion 152 between the first attachment device 164 and the fourth end 158 of the support portion 152. Movement along the Z-axis 174 is represented by movement perpendicular to both the X and Y axes 170, 172.

[0066] In Fig. 3, an exemplary first shape of the workpiece 134 is illustrated by a solid line and an exemplary second shape of the workpiece 134 is illustrated by a dotted line. The first shape is illustrated as a rectangular shape. The second shape is illustrated as a trapezoidal shape. The second shape of the workpiece is significantly larger than the first shape. However, the first and second shapes may also differ in shape and / or size. The second shape may be planar or non-planar.

[0067] Based on the first and second shapes of the workpiece 134, the positioning of the first and second fixtures 164, 166 of the end effector 132 is adjusted by the control module 104 to account for the shape change. Fig. 3, the first fixture 164 is adjusted closer to the third end 156 of the support portion 152 when the workpiece 134 is in the second mold than when the workpiece 134 is in the first mold. The second fixture 166 is adjusted closer to the fourth end 158 of the support portion 152 when the workpiece 134 is in the second mold than when the workpiece 134 is in the first mold. Accordingly, the first and second fixtures 164, 166 are adjusted to accommodate the larger size of the second mold.

[0068] Fig. 4 is a plan view of another attachment device 180. In some configurations of the end effector 132, the first and second attachment devices 164, 166 of the end effector 132 may be reached by the attachment device 180.

[0069] The mounting device 180 includes motors 182, a housing 184, and fingers 186. The motors 182 can be received in the support portion 152 of the end effector 132 and in the housing 184 of the mounting device 180 at opposite ends. The motors 182 can be servo motors or other suitable motors. In the illustrated example, four motors 182 are shown. However, a higher or lower number of motors 182 can be provided.

[0070] The housing 184 may have a fifth end 188 and a sixth end 190 opposite the fifth end 188. The housing 184 may also have a third side 192 and a fourth side 194 opposite the third side 192. The motors 182 may be attached to the third side 192 of the housing 184, and the pair of fingers 186 may extend from the fourth side 194 of the housing 184. However, the pair of fingers 186 may be attached to any suitable location on the housing 184.

[0071] Each of the fingers 186 may have a seventh end 196 and an eighth end 198 that is opposite the seventh end 196. The seventh ends 196 of the fingers 186 are positioned near (e.g., proximally) the housing 184. The eighth ends 198 of the fingers 186 are positioned distally to the housing 184. Additionally, each of the fingers 186 may include a first set of gestures 200 and a second set of gestures 202. The first set of gestures 200 may extend from the housing 184. The second set of gestures 202 is rotatably connected to the first set of gestures 200.

[0072] In the illustrated example, the first set of linkages 200 may include a first linkage 210, a second linkage 212, and a third linkage 214. The first, second, and third linkages 210, 212, 214 may extend longitudinally and be spaced apart from each other such that the second linkage 212 is disposed between the first and third linkages 210, 214. The second set of linkages 202 may include a fourth linkage 216 and a fifth linkage 218. The fourth and fifth linkages 216, 218 may extend longitudinally and be spaced apart from each other such that the fifth linkage 218 is disposed within the fourth linkage 216. A connecting linkage 220 may be disposed between the first and fourth linkages 210, 216 such that the first and fourth linkages 210, 216 are rotatably mounted at opposite ends of the connecting linkage 220.The second linkage 212 may be rotatably attached to the fifth linkage 218 on the connecting linkage 220. The third linkage 214 may be rotatably attached to the fifth linkage 218.

[0073] A gripper assembly 222 may be disposed at the eighth end 198 of each finger 186. The gripper assembly 222 may include a gripper base 224 fixedly attached to the second set of linkages 202 and a gripper 226 pivotally attached to the gripper base 224.

[0074] The workpiece 134 may be disposed between the grippers 226 of the fingers 186. The first and second sets of linkages 200, 202 of the fingers 186 are configured to rotate to grip and release the workpiece 134. For example, the fingers 186 may rotate inward to clamp the workpiece 134 and outward to release the workpiece 134. Additionally, each gripper 226 is configured to pivot relative to the gripper base 224 to grip the workpiece 134 at a suitable angle.

[0075] In some examples, e.g., when the robot system 100 includes the second adjustment module 112, an exemplary force sensor 228 may be disposed on a contact surface of the gripper 226. The force sensor 228 is configured to measure a force exerted by the gripper 226 on the workpiece 134 when the gripper 226 grips the workpiece 134.

[0076] The fingers 186 may be movable relative to the housing 184. In one example, the fingers 186 may be moved along the X-axis 170 and the Z-axis 174 and may be rotatable about the X-axis 170 and the Y-axis 172. The movement of the fingers 186 along the X-axis 170 is represented by movement into and out of the housing 184. The movement of the fingers along the Z-axis 174 is represented by movement along the fourth side 194 of the housing 184 between the fifth and sixth ends 188, 190 of the housing 184. Each of the fingers 186 may move independently; alternatively, the fingers 186 may move together.

[0077] Another exemplary end effector 232 is shown in Fig. 5-7. Fig. Figure 5 is a side view of the end effector 232 gripping the workpiece 134. Fig. 6 is a partial perspective view of an exemplary first attachment device 264 of the end effector 232. Fig. Figure 7 is a partial cross-sectional view of the first fastening device 264.

[0078] The end effector 232 may include a connector 250 and a support portion 252 extending between a third end 256 and a fourth end 258. The connector 250 and support portion 252 of the end effector 232 may be the same or substantially similar to the connector 150 and support portion 152 of the end effector 132. Therefore, these components will not be described again in detail.

[0079] Additionally, the end effector 232 may include the first fastening device 264 and a second fastening device 266.

[0080] The end effector 232 may also include a rail 268 attached to the support portion 252. The first attachment device 264, the second attachment device 266, or both the first and second attachment devices 264, 266 may be slidable along the rail 268. In the illustrated example, the rail 268 is disposed between the third end 256 of the support portion 252 and the second attachment device 266. The first attachment device 264 is slidable along the rail 268. In some configurations, a second rail may be disposed between the rail 268 and the fourth end 258 of the support portion 252. The second attachment device 266 may be slidable along the second rail.

[0081] In one example, the first fastening device 264, the second fastening device 266, or both the first and second fastening devices 264, 266 may be the same or a substantially similar device to the fastening device 180.

[0082] In the Fig. 6-7, the first fastening device 264 includes a rod 282, a receptacle 284, and a suction cup 286. The rod 282 extends between a fifth end 288 and a sixth end 290 opposite the fifth end 288. The rod 282 extends through the receptacle 284 such that the receptacle 284 is disposed between the fifth and sixth ends 288, 290 of the rod 282. The receptacle 284 is connected to the rail 268 and moves the first fastening device 264 along the rail 268. In one example, the receptacle 284 is received within the rail 268 and is configured to slide along the rail 268. In another example, the receptacle 284 includes teeth that engage with the teeth arranged on the rail 268, and rotation of the receptacle 284 moves the receptacle 284 along the rail 268.However, the receptacle 284 may also move along the rail 268 in any other suitable manner.

[0083] The suction cup 286 is disposed at the sixth end 290 of the rod 282. The suction cup 286 is configured to grip and release the workpiece 134. The suction cup 286 may be a spring-loaded suction cup. Accordingly, a spring 292 may be disposed within the rod 282 and positioned between the receptacle 284 and the suction cup 286.

[0084] In some configurations, the robot system 100 may include two robots. Fig. 8 is a perspective view of robot 130 attached to end effector 132 and an exemplary second robot 330 attached to a second end effector 332.

[0085] The second robot 330 may be the same or substantially similar to robot 130. Similarly, the second end effector 332 may be the same or substantially similar to end effector 132 or end effector 232. Accordingly, the second robot 330 and the second end effector 332 will not be described again in detail.

[0086] The robot 130 may be disposed on and grasp a first side 344 of the workpiece 134, and the second robot 330 may be disposed on and grasp a second side 346 of the workpiece 134. In the illustrated examples, the first side 344 is opposite the second side 346, such that the end effector 132 and the second end effector 332 grasp the workpiece 134 at opposite ends of the workpiece 134. However, the first side 344 may be adjacent to the second side 346 and / or disposed at a suitable angle to the second side 346 of the workpiece.

[0087] Fig. 9 is a flowchart illustrating an example method 500 for operating the example robot system 100.

[0088] At 502, the control module 104 determines the path of the one or more robots 102 based on the first shape (e.g., the shape before passing through the machine 109) of the workpiece 106 and the target shape of the workpiece 106. The control module 104 determines the location at which the at least one fixture 122 should grip the workpiece 106 based on the first shape of the workpiece 106 and the path of the one or more robots 102. The control module 104 determines the first configuration of the end effector 108 based on the first shape of the workpiece 106. The configuration of the end effector 108 is set to the first configuration by the control module 104. In some examples, the control module 104 may actuate the end effector 108 and preload the workpiece 106.

[0089] At 504, the control module 104 actuates the end effector 108 and grips and holds the workpiece 106 by actuating one or more fasteners 122 of the end effector 108.

[0090] At 506, the cameras 114 capture images of the workpiece 106. For example, the cameras 114 capture initial images of the workpiece 106 (e.g., images before the workpiece 106 passes through the machine 109). The cameras 114 transmit the images to the first setup module 110. The first setup module 110 determines a current shape of the workpiece 106 based on at least one of the images.

[0091] Optionally, at 508, the force sensors 120 measure the forces exerted by the one or more fixtures 122 of the end effector 108 on the workpiece 106 to grip and hold the workpiece 106. For example, the force sensors 120 measure first forces of the workpiece 106 (e.g.,

[0092] Forces before the workpiece 106 passes through the machine 109). The force sensors 120 transmit the force measurements to the second adjustment module 112. The second adjustment module 112 determines a current shape of the workpiece 106 based on at least one of the force measurements.

[0093] At 510, the control module 104 controls the one or more robots 102 to guide the workpiece 106 through the machine 109 based on the determined path of the one or more robots 102. The end effector 108 continues to grip and hold the workpiece 106. As the workpiece 106 is guided through the machine 109, the cameras 114 continue to capture images of the workpiece 106 and transmit the images to the first adjustment module 110, and optionally, the force sensors 120 continue to measure forces and transmit the forces to the second adjustment module 112. In some examples, the control module 104 may adjust the configuration of the end effector 108 based on the current shape of the workpiece 106.

[0094] At 512, the cameras 114 capture second images of the workpiece after the workpiece 106 has passed through the machine 109. Image capture can then be interrupted (at least temporarily). The cameras 114 transmit the second images to the first adjustment module 110.

[0095] At 514, the first adjustment module 110 determines the second shape of the workpiece 106 (e.g., the shape of the workpiece 106 after passing through the machine 109) based on at least one of the second images. Additionally, the first adjustment module 110 determines the first change to the workpiece 106 based on at least one of the first images and at least one of the second images. The first adjustment module 110 transmits the second shape of the workpiece 106 and the first change to the workpiece 106 to the control module 104.

[0096] Optionally, at 516, the force sensors 120 measure second forces exerted by the one or more fixtures 122 of the end effector 108 on the workpiece 106 after the workpiece 106 has passed through the machine 109. The force measurement may then be interrupted (at least temporarily).

[0097] Optionally, at 518, the second adjustment module 112 additionally or alternatively determines the second shape of the workpiece 106 based on at least one of the second force measurements. For example, the second adjustment module 112 determines the material strain in the workpiece 106 based on at least one of the second force measurements and determines the second shape of the workpiece 106 based on the material strain. Additionally, the second adjustment module 112 determines the second change in the workpiece 106 based on at least one of the first force measurements and at least one of the second force measurements. For example, the second adjustment module 112 may determine the second change based on a change between the first shape and the second shape (determined based on the second force measurement(s)). The second adjustment module 112 transmits the second shape of the workpiece 106 and the second change in the workpiece 106 to the control module 104.

[0098] At 520, the control module 104 controls the one or more fixtures 122 of the end effector 108 and releases the workpiece 106.

[0099] At 522, the control module 104 determines whether the workpiece 106 (the current shape) has the target shape by comparing the current shape of the workpiece 106 to the target shape of the workpiece. In some examples, the target shape may be a predetermined CAD model for the workpiece 106.

[0100] If 522 is true (e.g., the workpiece 106 has the target shape), the method ends. The workpiece 106 may be ready for assembly on a vehicle.

[0101] If 522 is false (e.g., the workpiece 106 does not have the target shape), the method continues to 522. At 524, the control module 104 determines the path of the one or more robots 102 based on at least one of the second shape of the workpiece 106, the first or second change to the workpiece 106, and the target shape of the workpiece 106. Additionally, the control module 104 determines the second configuration of the end effector 108 based on at least one of the first and second changes to the workpiece 106. The control module 104 sets the configuration of the end effector 108 to the second configuration such that the second configuration is suitable for the second shape of the workpiece 106.

[0102] The method 500 continues to 504, where the control module 104 actuates the end effector 108 to again grasp and hold the workpiece 106 by actuating one or more fixtures 122 of the end effector 108. The end effector 108 may grasp the workpiece 106 at the same or a different location than during the previous pass through the machine 109 based on at least one of the first and second changes to the workpiece 106 and the path of the one or more robots 102 for the subsequent pass through the machine 109. The method 500 repeats until 522 is true.

[0103] The foregoing description is merely illustrative and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure may be embodied in a variety of forms. Therefore, while this disclosure includes specific examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon examination of the drawings, the specification, and the following claims. It is to be understood that one or more steps within a method may be performed in different orders (or simultaneously) without altering the principles of the present disclosure.Furthermore, although the above embodiments are each described above as having certain features, any one or more of these features described with respect to one embodiment of the disclosure may be implemented and / or combined with features of any of the other embodiments, even if this combination is not expressly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments remain within the scope of this disclosure.

[0104] 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," "adjacent," "on," "over," "under," and "disposed." When a relationship between a first and a second element is not explicitly described as "direct" in the above disclosure, that relationship may be a direct relationship, with no other intervening elements present between the first and second elements; or it may be an indirect relationship, with one or more intervening elements (either spatial or functional) present between the first and second elements.As used herein, the phrase "A, B, and / or C" should be construed as logical (A ORed with B, ORed with C) using a non-exclusive logical "OR" operation, rather than as "at least one of A, at least one of B, and at least one of C."

[0105] In the figures, the direction of an arrow, as indicated by the arrowhead, generally illustrates the flow of information (e.g., data or instructions) of interest to the illustration. For example, if element A and element B exchange a variety of information, but the information transmitted from element A to element B is relevant to the illustration, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is transmitted from element B to element A. Further, for information sent from element A to element B, element B may send requests for or acknowledgments of receipt of the information to element A.

[0106] In this application, including the definitions below, the term "module" or the term "controller" may be replaced by the term "circuit".The term “module” may refer to, be part of, or include: 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 grouped) that executes code; a memory circuit (shared, dedicated, or grouped) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality; or a combination of some or all of the foregoing components, such as in a system-on-chip.

[0107] The module may include one or more interface circuits. In some examples, the interface circuits may include wired or wireless interfaces connected to a local area network (LAN), the Internet, a wide area network (WAN), or combinations thereof. The functionality of a given module of the present disclosure may be distributed among multiple modules connected via interface circuits. For example, multiple modules may enable load balancing. In another example, a server module (also known as a remote or cloud module) may perform some functionality on behalf of a client module.

[0108] As used above, the term "code" may include software, firmware, and / or microcode and may refer to programs, routines, functions, classes, data structures, and / or objects. The term "shared processor circuitry" includes a single processor circuitry that executes, in whole or in part, code from multiple modules. The term "group processor circuitry" includes a processor circuitry that, in combination with additional processor circuitries, executes, in part or in whole, code from one or more modules. The term "multiple processor circuitries" includes multiple processor circuitries on individual chips, multiple processor circuitries on a single chip, multiple cores of a single processor circuitry, multiple threads of a single processor circuitry, or a combination of the above possibilities.The term "shared memory circuit" refers to a single memory circuit that stores some or all of the code from multiple modules. The term "group memory circuit" refers to a memory circuit that, in combination with additional memory, stores some or all of the code from one or more modules.

[0109] The term memory circuit is a subset of the term computer-readable medium. The term "computer-readable medium," as used herein, does not include transitory electrical or electromagnetic signals propagated through a medium (such as a carrier wave); the term "computer-readable medium" can therefore be considered tangible and non-transitory.Non-limiting examples of a non-transitory, tangible, computer-readable medium include non-volatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only memory circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).

[0110] The devices and methods described in this application may be implemented in part or in full by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications that can be converted into computer programs through the routine work of a skilled technician or programmer.

[0111] The computer programs contain processor-executable instructions stored on at least one non-transitory, tangible, computer-readable medium. The computer programs may also contain or rely on stored data. The computer programs may 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, etc.

[0112] The computer programs may comprise: (i) descriptive text to be parsed, e.g. B. 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 for execution by an interpreter, (v) source code for compilation and execution by a just-in-time compiler, etc. By way of example only, source code can be written using the syntax of languages ​​including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, Javascript®, HTML5 (Hypertext Markup Language 5th revision), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB, SIMULINK and Python®.

Claims

[1] Robot system (100) for forming a formable workpiece (106), the robot system (100) comprising: a robot (102) configured to guide the workpiece (106) through a machine (109); an end effector (108) configured to be attached to the robot (102) and configured to grip and release the workpiece (106), the end effector (108) being adjustable to a variety of different configurations; a setting module (110) configured to determine a change in the workpiece (106) from (a) a first shape of the workpiece (106) before the workpiece (106) passes through the machine (109) to (b) a second shape of the workpiece (106) after the workpiece (106) passes through the machine (109); and a control module (104) configured to adjust a current configuration of the end effector (108) to a second configuration based on the change of the workpiece (106) from (a) the first shape to (b) the second shape. [2] The robot system (100) of claim 1, further comprising: a camera (114) configured to capture (a) a first image of the workpiece (106) before the workpiece (106) passes through the machine (109) and (b) a second image of the workpiece (106) after the workpiece (106) passes through the machine (109), wherein the adjustment module (110) is configured to determine the first shape of the workpiece (106) based on the first image and to determine the second shape of the workpiece (106) based on the second image. [3] Robot system (100) according to claim 1, further comprising: at least one camera (114) configured to capture an image of the workpiece (106) as the workpiece (106) is guided through the machine (109), wherein the adjustment module (110) is configured to determine a current shape of the workpiece (106) based on the image, and wherein the control module (104) is configured to adjust the current configuration of the end effector (108) based on the current shape of the workpiece (106) and during the passage of the workpiece (106) through the machine (109). [4] Robot system (100) according to claim 1, wherein: the end effector (108) includes a force sensor configured to measure (a) a first force exerted by the end effector (108) on the workpiece (106) before the workpiece (106) passes through the machine (109), and (b) a second force exerted by the end effector (108) on the workpiece (106) after the workpiece (106) passes through the machine (109); and the adjustment module (110) is configured to determine the first shape based on the first force and the second shape based on the second force. [5] Robot system (100) according to claim 1, wherein: the end effector (108) includes a force sensor configured to measure a force exerted by the end effector (108) on the workpiece (106) during the passage of the workpiece (106) through the machine (109); the adjustment module (110) is configured to determine a current shape of the workpiece (106) based on the force; and the control module (104) is configured to adjust the current configuration of the end effector (108) based on the current shape of the workpiece (106) during the passage of the workpiece (106) through the machine (109). [6] Robot system (100) according to claim 1, wherein: the end effector (108) comprises: a support section (152) and a fastening device (122) attached to the support portion (152) and configured to grip and release the workpiece (106); and the control module (104) is configured to adjust the current configuration of the end effector (108) by adjusting the mounting device (122). [7] The robot system (100) of claim 6, wherein the control module (104) is configured to move the attachment device (122) in at least one of the X, Y, and Z directions, the X, Y, and Z directions being perpendicular to each other. [8] The robot system (100) of claim 6, wherein the control module (104) is configured to rotate the fixture (122) about at least an X-axis, a Y-axis, and a Z-axis, the X-, Y-, and Z-axes being perpendicular to each other. [9] The robot system (100) of claim 6, wherein the attachment device (122) comprises a first attachment device (164) movable relative to the support portion of the end effector (108), and the end effector (108) further comprises a second attachment device (166) attached to the support portion. [10] The robot system (100) of claim 1, wherein the machine (109) is at least one of an English wheel or a jackhammer.

Images