ROBOT GRABLER DEVICE FOR COUPLING TO A VEHICLE COMPONENT

Abstract

A robot gripper assembly for coupling to a vehicle component includes an end effector comprising a frame, at least one gripper, and a first mold. The gripper is mounted on the frame and configured to grasp the first vehicle component. The first mold is mounted on the frame and configured to align the first vehicle component with the first end effector. The first mold is made of an elastomer material and has a shape that corresponds to the shape of the first vehicle component.

Description

AREA OF TECHNOLOGY The present disclosure relates to a robot gripper device for coupling to a vehicle component. GENERAL STATE OF THE ART The statements in this section merely provide background information regarding the present disclosure and may not represent the state of the art. Industrial robots are used for a variety of manufacturing processes, including welding and moving parts from one location to another, such as picking parts from a storage location and moving them to an assembly station. Automating the movement of some vehicle parts can be challenging due to the lack of proper part handling and mechanical repeatability. These problems relating to the automation of component handling, along with other problems relating to component processing, are addressed by the present disclosure. SUMMARY This section provides a general summary of the revelation and is not a comprehensive revelation of its full scope or all of its features. In one embodiment, the present disclosure provides a robot gripper device for coupling to a first vehicle component. The robot gripper device includes a first end effector comprising a frame, at least one gripper, and a first mold. The gripper is mounted on the frame and is configured to grasp the first vehicle component. The first mold is mounted on the frame and is configured to align the first vehicle component with respect to the first end effector. The first mold is made of an elastomeric material and has a shape that corresponds to the shape of the first vehicle component. In variations of the robot gripper device described in the preceding paragraph, which can be implemented individually or in any combination, the following applies: The gripper is a vacuum gripper; the gripper includes a plurality of grippers mounted on different sections of the frame; the mold is a lattice mold containing a plurality of openings; the mold includes a body and end sections, the end sections tapering inwards towards the body; the frame includes a main frame and a first and a second frame element spaced apart and extending from the main frame; the gripper includes a first gripper mounted on the first frame element and a second gripper mounted on the second frame element; the first mold is mounted on the first frame element;and a second mold is mounted on the second frame member and is configured to further align the first vehicle component with respect to the first end effector, the second mold having a shape corresponding to the shape of the first vehicle component and having a rigidity greater than the rigidity of the first mold; the first end effector further includes a restraint feature mounted on one of the first and second frame members and configured to couple a second vehicle component to the first end effector; a second end effector comprising a pair of opposing grippers movable between a first position in which the pair of opposing grippers engages a second vehicle component and a second position in which the pair of opposing grippers is released from the second vehicle component;a mounting feature coupled to one of the opposing grippers and configured to grip the second vehicle component independently of the pair of opposing grippers; the mounting feature includes one or more magnets at least partially arranged therein; and the robot gripper assembly further includes a robot arm, the frame being coupled to one end of the robot arm. In one embodiment, the present disclosure provides a robot gripper device for coupling to a first vehicle component. The robot gripper device includes a first end effector comprising a frame, a plurality of grippers, and a plurality of molds. The plurality of grippers is mounted on the frame and is configured to grasp the first vehicle component. The plurality of molds is mounted on the frame and is configured to align the first vehicle component with respect to the first end effector, each mold of the plurality having a shape corresponding to a shape of the first vehicle component. One mold of the plurality has a first rigidity and is a lattice mold with a plurality of openings. Another mold of the plurality is spaced apart from the first mold and has a second rigidity greater than the first rigidity.In variations of the robot gripper device described in the preceding paragraph, which can be implemented individually or in any combination, the following applies: The plurality of grippers are vacuum grippers; each mold of the plurality of molds comprises a body and end sections, the end sections tapering inwards towards the body; the frame comprises a main frame and a first and a second frame element spaced apart from each other and extending from the main frame; the plurality of grippers comprises a first gripper mounted on the first frame element and a second gripper mounted on the second frame element; one mold is mounted on the first frame element; and the other mold is mounted on the second frame element;The first end effector includes a retention feature mounted on one of the first and second frame elements and configured to couple a second vehicle component to the first end effector; a second end effector comprising a pair of opposing grippers movable between a first position in which the pair of opposing grippers engages a second vehicle component and a second position in which the pair of opposing grippers is released from the second vehicle component; a mounting feature coupled to one of the opposing grippers and configured to grip the second vehicle component independently of the pair of opposing grippers; the mounting feature includes one or more magnets at least partially arranged therein;a controller that communicates with the second end effector and is configured to: instruct the second end effector to grasp the second vehicle component using the pair of opposing grippers; instruct the second end effector to move the second vehicle component to the first end effector and to position the second vehicle component at the restraint feature; and instruct the second end effector to grasp the second vehicle component using the assembly feature and to remove the vehicle component from the restraint feature; and the robot gripper assembly further includes a robot arm, the frame being coupled to one end of the robot arm. Further areas of application will become apparent from the description provided in this document. It is understood that the description and specific examples serve only for illustration and are not intended to limit the scope of this disclosure. DRAWINGS For a comprehensive understanding of the disclosure, various embodiments thereof are now described by way of example with reference to the accompanying drawings, in which the following applies: Fig. 1 is a perspective view of a system for handling a vehicle component according to the principles of the present disclosure; Fig. 2 is a perspective view of a vehicle body of the vehicle with the vehicle component installed therein; Fig. 3 is a perspective view of a pillar of the vehicle from Fig. 2, which includes a seat belt; Figs. 4A-4E are schematic views showing a first component of the vehicle component coupled to the vehicle body from Fig. 2; Fig. 5A is a perspective view of a robot of the system placing a section of the seat belt on another robot of the system; Fig. 5B is a perspective view of a robot of the system from Fig.1, which re-grasps the section of the seat belt; Fig. 5C is a perspective view of one of the robots of the system from Fig. 1, which couples the section of the seat belt to the vehicle body; Figs. 6A-6D are schematic views showing a second component of the vehicle component, which is coupled to the vehicle body from Fig. 2; Fig. 7 is a schematic block diagram showing the components of the system from Fig. 1 according to the teachings of the present disclosure; Fig. 8 is a perspective view of an end effector of one of the robots of the system from Fig. 1; Fig. 9A is a perspective view of an end effector of another robot of the system from Fig. 1 in the closed position; Fig. 9B is a perspective view of the end effector from Fig. 9A in the open position; Fig. 10 is a flowchart showing an algorithm for handling the first component of the system from Fig.1 according to the teachings of the present revelation; and Fig. 11 is a flowchart showing an algorithm for handling the second component of the system from Fig. 1 according to the teachings of the present revelation. The drawings described in this document serve only for illustration and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION The following description is merely exemplary and is not intended to limit the present disclosure, application, or uses. It is understood that in all drawings, corresponding reference numerals indicate identical or corresponding parts and features. With reference to Fig. 1, a system 10 for handling one or more vehicle components 12 (shown only in the figure) is illustrated. Handling the vehicle components 12 can include removing the vehicle components 12 from a parts carrier (e.g., a floor rack), manipulating parts of the vehicle components 12, and / or installing the vehicle components 12 into a vehicle 17. The system 10 enables the handling of the vehicle components 12 with little to no human intervention. In this way, the handling of the vehicle components 12 can be automated to, for example, increase productivity, reduce cycle time, and minimize variations and errors. In the illustrated example, the vehicle components 12 can include vehicle pillar trim components.This means that automating vehicle pillar components can be challenging due to the need to grip complex components, protect surfaces, and feed components through confined spaces. System 10 of this disclosure provides the adaptation of vehicle components 12, such as vehicle pillar components, to better support automation. It is understood that the vehicle components 12 can be other vehicle components besides vehicle pillar trim components. Referring to Fig. 2, the vehicle 17 includes a vehicle body structure 14, which has a plurality of pillars 16, a pair of side rails 18 (only one is shown in the figure), and sills 20 (only one is shown in the figure). The pillars 16, the sills 20, and the side rails 18 work together to define door openings 22 in the vehicle body structure 14. Doors (not shown) are rotatably coupled to the vehicle body structure 14, moving between a closed position, in which the doors are positioned within the door openings 22, and an open position, in which the doors are removed from the door openings 22. With further reference to Fig. 3, safety belts 24 are coupled to the vehicle 17 (e.g. a pillar 16 of the vehicle 17) and each of these can include, among other things, a belt tensioner 24a, a webbing 24b and a tongue 24c.The belt tensioner 24a allows the webbing 24b to fit snugly against the occupant's body. The tongue 24c is coupled to the webbing 24b and fits into a buckle (not shown) to secure the seat belt 24. Referring again to Fig. 1, the system comprises 10 robots 26, 28, the vehicle component 12, and a controller 30 (Fig. 7). As described in more detail below, the robot 26 is configured to pick up parts of the vehicle component 12, move parts of the vehicle component 12 from a work surface, for example, to the vehicle 17, manipulate parts of the vehicle component 12 relative to the vehicle 17 (e.g., rotate them), and couple parts of the vehicle component 12 to the vehicle 17. The robot 26 includes a robot arm 26a and a robot gripper structure or robot gripper end effector 26b. The robot arm 26a comprises a plurality of segments connected to each other at joints, thus enabling the robot 26 to have multiple degrees of freedom. The robot arm 26a is also secured at a first end to the work surface.In some variations, the robot arm 26a includes an optional adapter (not shown) adapted for securing to the work surface. In some configurations, the robot 26 is detached from the work surface and partially or fully autonomous, configured to move autonomously to the workpiece carrier (not shown) and / or the work surface as instructed by the controller 30. To enable autonomous movement, the controller 30 is configured to control various motion systems of the robot 26 based on location data obtained from one or more sensors. In an example application, the motion systems may include drive systems and / or steering systems for controlling wheels, and the sensors providing location data may include, among others, a GNSS sensor, an imaging sensor, and a local position sensor. The robot gripper structure 26b is secured to the robot arm 26a and is configured to pick up the parts of the vehicle component 12. In this way, the robot gripper structure 26b can grasp the parts of the vehicle component 12 and move them from one location to another, as described in more detail below. The robot gripper structure 26b can also manipulate the parts relative to the vehicle 17 (e.g., rotate the parts) to facilitate the coupling of the parts of the vehicle component 12 to the vehicle 17. Referring to Fig. 8, the robot gripper structure 26b comprises a frame 32, one or more grippers 34a, 34b, one or more molds 36a, 36b, and a retaining feature 37. The frame 32 is coupled to one end of the robot arm 26a and carries the grippers 34a, 34b and the molds 36a, 36b. The frame 32 includes a main frame 38 and frame elements 40a, 40b. In the illustrated example, the main frame 38 has a length greater than the lengths of the frame elements 40a, 40b. In some embodiments, each of the frame elements 40a, 40b can have a length equal to or greater than the length of the main frame 38. In the illustrated example, frame element 40a extends from the main frame 38 to or near a first end, and frame element 40b extends from the main frame 38 to or near a second end opposite the first end (i.e.,The first and second frame elements 40a, 40b are spaced apart from each other. In the illustrated example, the first and second frame elements 40a, 40b extend perpendicularly from the main frame 38. In other variations, the first and second frame elements 40a, 40b may extend from the main frame 38 at a non-right angle (e.g., an obtuse angle or an acute angle). In the illustrated example, the main frame 38 and the first and second frame elements 40a, 40b are combined to form a single structure. In some embodiments, the frame 32 may be manufactured, for example, using an injection molding process, so that the frame 32 is a single, monolithic part. Grippers 34a and 34b are mounted on the frame 32 and are configured to grip the vehicle component 12. In the illustrated example, grippers 34a and 34b are vacuum suction grippers or suction cup grippers, which grip or lift the vehicle component 12 using suction. In the illustrated example, each gripper 34a and 34b is mounted on the frame 32 using a mounting mechanism 40. In some embodiments, each gripper 34a and 34b can be mounted at a predetermined position on the frame 32 to facilitate lifting or gripping the vehicle component 12. That is, gripper 34a can be mounted on frame element 40a, and gripper 34b can be mounted on frame element 40b. In the illustrated example, grippers 34a and 34b are located between the molds 36a and 36b. In some embodiments, the casting molds 36a, 36b can be located between the grippers 34a, 34b.In some embodiments, the robot gripper structure 26b can include additional grippers (not shown) mounted on the main frame 38 or other parts of the frame 32 to further facilitate lifting or gripping the vehicle component 12. It is understood that the grippers 34a and 34b can grip or pick up parts independently of each other as well as together. The molds 36a, 36b are mounted on the frame 32 and are configured to align the vehicle component 12 with respect to the end effector 26b before the end effector grasps or lifts the vehicle component 12. Each mold 36a, 36b has a shape corresponding to a shape (e.g., an outer profile) of the vehicle component 12 and includes a body 42 and end sections 44a, 44b. The end sections 44a, 44b taper inward toward the body 42. In other words, the contact surfaces (surfaces of the molds 36a, 36b that come into contact with the vehicle component 12) of the end sections 44a, 44b taper inward toward the body 42. This enables the vehicle component 12 to be aligned with respect to the end effector 26b. In the illustrated example, the mold 36a is connected via fasteners 47a (e.g.The mold 36b is mounted to the frame element 40a by means of fasteners 47b (e.g., screws, bolts, rivets), and the mold 36b is mounted to the frame element 40b by means of fasteners 47b (e.g., screws, bolts, rivets). That is, the fasteners 47a can extend through the body 42 of the mold 36a and the frame element 40a to couple the mold 36a to the frame element 40a, and the fasteners 47b can extend through the body 42 of the mold 36b and the frame element 40b to couple the mold 36b to the frame element 40b. In some embodiments, additional molds (not shown) can be attached to the frame 32 to further facilitate the alignment of the vehicle component 12 with respect to the end effector 26b. Each mold 36a, 36b has a length that extends parallel to a length of the frame element 40a, 40b. In the illustrated example, mold 36a can have a rigidity greater than that of mold 36b. In other words, mold 36a can have a stiffness greater than that of mold 36b. In this way, mold 36a is less likely to be removed from the mold than mold 36b. Mold 36a has a recess configured to receive a section of the vehicle component 12. Mold 36a also includes one or more projections 50 extending from it, configured to engage in grooves of the vehicle component 12. This further aligns the vehicle component 12 with the end effector 26b. The projections 50 are spaced apart from each other and extend downwards over a surface of the mold 36a (the projections 50 extend into the recess).The projections 50 can extend downwards from the body 42 and / or the end sections 44a, 44b of the mold 36a. Mold 36b can be made of a softer material than mold 36a. For example, mold 36b can be made of a rubber material, such as thermoplastic polyurethane (TPU), and mold 36a can be made of a plastic. In this way, mold 36b can contact Class-A surfaces (occupant-facing surfaces) of the vehicle component 12 during the assembly process without deforming the surfaces. In the illustrated example, mold 36b is a lattice mold that includes a plurality of openings 54. In other words, the openings 54 can be formed in the body 42 of mold 36b and the end sections 44a, 44b of mold 36b. In this way, the mold 36b incorporates a compliant geometry to further prevent distortion of the surfaces of the vehicle component 12 during the assembly process.Mold 36b has a recess configured to accommodate a section of vehicle component 12. The restraint feature 37 is mounted on one of the frame elements 40a, 40b and is configured to removably couple a section (e.g., the belt tensioner 24a) of the seat belt 24 to it, as described in more detail below. In the illustrated example, the restraint feature 37 is coupled to the frame element 40a. In some embodiments, the restraint feature 37 may be coupled to the frame element 40b. The restraint feature 37 may define a slot that temporarily receives the section of the seat belt 24. The robot 28 is configured to pick up parts of the seat belt 24, guide or direct parts of the seat belt 24 through the vehicle component 12, manipulate (e.g., rotate) parts of the seat belt 24 relative to the vehicle 17 and / or the vehicle component 12, and couple parts of the seat belt 24 to the vehicle 17. The robot 28 includes a robot arm 28a and a robot gripper structure or robot gripper end effector 28b. The robot arm 28a comprises a multitude of segments connected to each other at joints, enabling the robot 28 to have multiple degrees of freedom. The robot arm 28a is also secured to the work surface at a first end. In some variations, the robot arm 28a includes an optional adapter (not shown) adapted for securing to the work surface.In some embodiments, the robot 28 is detached from the work surface and partially or fully autonomous, configured to move autonomously to the workpiece carrier (not shown) and / or the work surface as instructed by the controller 30. To enable autonomous movement, the controller 30 is configured to control various motion systems of the robot 28 based on location data obtained from one or more sensors. In an example application, the motion systems may include drive systems and steering systems for controlling wheels, and the sensors providing location data may include, among others, a GNSS sensor, an imaging sensor, and a local position sensor. The robot gripper structure 28b is secured to the robot arm 28a and is configured to pick up the parts of the seat belt 24. In this way, the robot gripper structure 28b can grasp the parts of the seat belt 24 and guide them through the vehicle component 12, as described in more detail below. The robot gripper structure 28b can also manipulate the parts relative to the vehicle 17 (e.g., rotate the parts). Referring to Fig. 9A and Fig. 9B, the robot gripper structure 28b comprises an actuator assembly 58 and a pair of opposing grippers 60. The actuator assembly 58 is secured to a second end of the robot arm 28a. The actuator assembly 58 includes a body 62, a motor 63 (Fig. 7), and a pair of movable elements or arms 64. The body 62 is secured to the second end of the robot arm 28a. The motor 63 is associated with the body 62 (e.g., located within the body 62) and is electrically connected to the controller 30. The controller 30 can communicate with the motor 63, for example, via an internet, Wi-Fi, Bluetooth®, Zigbee®, powerline carrier communication (PLCC), or cellular connection, or any other wired or wireless communication protocol. The motor 63 can be operated in either an OFF mode or an ON mode.In one embodiment, the motor 63 can be an electric motor, such as a brushless drive motor. Each arm 64 is operatively connected to the motor 63 via a respective rail or connecting element (not shown) and is allowed to move in a transverse direction (i.e., perpendicular to a longitudinal direction of the arm 64). For example, when the motor 63 is in OFF mode, the arms 64 are prevented from moving in the transverse direction. When the motor 63 is in ON mode, the arms 64 are allowed to move in the transverse direction between an open state and a closed state. The pair of grippers 60 is secured to respective arms 64 and is movable in a transverse direction between a first position, in which the pair of opposing grippers 60 engages a section or part (e.g., the belt tensioner 24a) of the seat belt 24, and a second movable position, in which the pair of opposing grippers 60 is released from the section of the seat belt 24. In other words, each gripper 60 is secured to its respective arm 64 such that when the respective arm 64 is moved into the closed position, the gripper 60 is moved into the closed position (Fig. 9A), and when the respective arm 64 is in the open position, the gripper 60 is in the open position (Fig. 9B). In the illustrated example, each gripper 60 includes an attachment section 66a and an engagement section 66b. The attachment section 66a is located near or at a first end 60a of the gripper 60 and includes a recess 68 and a plurality of openings (not specifically shown). The recess 68 may be formed on an inner surface 72a of the gripper 60 and may accommodate a section of a respective arm 64. The openings may be spaced apart and may extend from an outer surface 72b of the gripper 60 to the recess 68 formed on the inner surface 72a of the gripper 60. In this way, mechanical fasteners (not shown) may extend through the respective arm 64 and the openings, thereby securing the respective arm 64 and the gripper 60 to one another. The engagement section 66b is located near or at a second end 60b of the gripper 60 and includes a mounting feature 76 configured to engage a portion of the safety belt 24. In the illustrated example, the mounting feature 76 is a groove formed in the engagement section 66b of the gripper 60 and open through the second end 60b of the gripper 60. A raised feature 78 may extend from an arcuate surface 80 of the groove and may be received in a perforation of the portion of the safety belt 24. This prevents movement between the grippers 60 and the portion of the safety belt 24 when the grippers 60 engage the portion of the safety belt 24 in the closed position. A semicircular lip 84 extends outward from the arcuate surface 80 of the groove and may be received in a slot of the portion of the safety belt 24.In this way, axial movement between the grippers 60 and the part of the safety belt 24 is prevented when the grippers 60 engage in the section of the safety belt 24 in the closed position. A mounting feature 88 is coupled to one of the grippers 60 and is configured to grip the portion (the belt tensioner 24a) of the seat belt 24 independently of the pair of opposing grippers 60. In the illustrated example, the mounting feature 88 includes a body 90 and a plurality of pairs of fingers 92a, 92b extending from a surface 91 of the body 90. The first pair of fingers 92a and the second pair of fingers 92b may be spaced apart. In this way, the portion of the seat belt 24 can be positioned between the pairs of fingers 92a, 92b. One or more permanent magnets 94, such as rare-earth magnets, may be arranged within the body 90 and may be exposed at the surface 91 of the body 90. In this way, the magnets 94 are attracted to the part of the safety belt 24 when the part of the safety belt 24 is positioned between the pairs of fingers 92a, 92b.This means that the permanent magnet 94 generates a magnetic force that is attracted to the metallic part of the safety belt 24. In this way, the magnets 94 and the metallic part of the safety belt 24 are magnetically coupled to each other, further coupling the part of the safety belt 24 to the mounting feature 88. It is understood that the grippers 60 and the mounting feature 88 can be configured to grasp different sections of the part of the safety belt 24. That is, the grippers 60 can grasp one end (e.g., an axial end) of the part of the safety belt 24, while the mounting feature 88 can grasp a region between the ends of the part of the safety belt 24 (i.e., around a cylindrical surface). In the illustrated example, the gripper 60 can be manufactured (e.g., injection molded) to incorporate the mounting feature 88.In some embodiments, the mounting feature 88 can be a separate component coupled to the gripper 60, thus forming a unified structure. The robot 28 may also optionally include vision sensors that collect visual image data and transmit the data to the controller 30. Based on the visual image data, the controller 30 provides instructions for operating the robot 28. In particular, the controller 30 provides instructions for operating the robot 28 to grasp and move the part of the seat belt 24. An example of such a vision sensor is disclosed in US patent application No. XX / 000,000 entitled “SYSTEM FOR HANDLING ELECTRICAL COMPONENTS FOR VEHICLE”, which is jointly owned with the present application and whose contents are incorporated in full into this document by reference. Referring to Fig. 7, the controller 30 communicates with the robots 26 and 28 and can monitor and control their operations based on the received data. In one example, the controller 30 communicates with the robots 26 and 28 using a wired or wireless communication protocol (e.g., a Bluetooth®-type protocol, a cellular protocol, a wireless fidelity (Wi-Fi)-type protocol, a near-field communication (NFC) protocol, or an ultra-wideband (UWB) protocol). The robots 26 and 28 and the controller 30 form a robot gripper assembly. With reference to Figures 4A-4E and 9, an exemplary control algorithm 200 for assembling a trim panel or a first vehicle component 12a of vehicle component 12 in the vehicle 17 is illustrated. Machining can begin as soon as the first vehicle component 12a has been moved from the parts carrier (not shown) to the work surface and / or the vehicle body structure 14 arrives at a workstation where the first vehicle component 12a and the robots 26, 28 are located. At 204, the control algorithm instructs the robot 26, using the controller 30, to grasp or pick up the first vehicle component 12a of vehicle component 12 (Fig. 4A) using the end effector 26b. The first vehicle component 12a may be located on a rack or storage area that prevents movement of the first vehicle component 12a before it is picked up by the robot 26.At 208, the control algorithm instructs the robot 26, using the controller 30, to move the first vehicle component 12a to the vehicle column 16 of the vehicle body structure 14, such that an opening 72 of the first vehicle component 12a receives a section of the seatbelt tensioner 24a (Fig. 4B; i.e., the seatbelt tensioner 24a is received at least partially through the opening 72 of the first vehicle component 12a). In some embodiments, the robot 26 can move the first vehicle component 12a to the vehicle column 16 in such a way that the seatbelt tensioner 24a is located at the opening 72 of the first vehicle component 12a without being partially received within the opening 72 of the first vehicle component 12a. At 212, the control algorithm instructs the robot 28, using the controller 30, to grasp the belt tensioner 24a using the end effector 28b and to guide the belt tensioner 24a, the tongue 24c, and a section of the webbing 24b through the opening 72 of the first vehicle component 12a (Fig. 4C and Fig. 4D). The robot 26 can move the first vehicle component 12a and / or the robot 28 can move (e.g., rotate) the belt tensioner 24a to reposition the first vehicle component 12a relative to the second robot 28 to facilitate the insertion of the belt tensioner 24a, the tongue 24c, and the section of webbing 24b through the opening 72 of the first vehicle component 12a. For example, the belt tensioner 24a can be rotated and then guided through the opening 72 of the first vehicle component 12a before the first vehicle component 12a is repositioned to guide the tongue 24c through the opening 72.It is understood that the belt tensioner 24a is temporarily located on the pillar 16 of the vehicle body structure 14. That is, in the illustrated example, a bracket 70 (Fig. 4A) can be secured to the pillar 16, and the belt tensioner 24a can be removably coupled to the bracket 70. In this way, the robot 28 can detach the belt tensioner 24a from the bracket 70 in order to guide the belt tensioner 24a through the opening 72 of the first vehicle component 12a, as described above. It is also understood that during the process, the tongue 24c is temporarily held in a fixed position on the webbing 24b by means of a retaining feature, such as an elastic material, a clamp, or any other suitable retaining feature.The restraint feature can be removed from the tongue 24c once the vehicle component 12 is coupled to the pillar 16, thus allowing the tongue to move along the webbing 24b. At 216, the control algorithm instructs the robot 26, using the controller 30, to couple the first vehicle component 12a to the vehicle column 16 of the vehicle body structure 14 (Fig. 4E). In the illustrated example, the first vehicle component 12a is coupled to an upper section of the vehicle column 16 by a snap fastener, fastening means, or any other suitable attachment method. In some embodiments, the first vehicle component 12a may be coupled to a center or another location of the vehicle column 16. With reference to Figures 5A-5C, 6A-6D, and 10, an exemplary control algorithm 300 for assembling a trim panel or a second vehicle component 12b of the vehicle component 12 in the vehicle 17 is illustrated. Processing can begin as soon as the first vehicle component 12a has been coupled to the vehicle column 16. In Figure 304, the control algorithm instructs the robot 28, using the controller 30, to place a section of the seat belt 24 (e.g., the belt tensioner 24a) on the restraint feature 37 of the end effector 26b (Figure 5A). In this way, the section of the seat belt 24 is carried by the end effector 26b. At 308, the control algorithm instructs the robot 28, using the control 30, to re-grasp the belt tensioner 24a (Fig. 5B) using the mounting feature 88.This means that the robot 28 places the seatbelt tensioner 24a on the retaining feature 37 of the end effector 26b in order to grasp the seatbelt tensioner 24a again at a different location. In other words, the robot 28 first grasps an end section of the seatbelt tensioner 24a (e.g., an axial end) using the grippers 60 before grasping a middle section of the seatbelt tensioner 24a again using the mounting feature 88. At 312, the control algorithm instructs the robot 28, using the controller 30, to couple the seatbelt tensioner 24a to the vehicle body structure 14 (Fig. 5C). That is, the robot 28 can couple the seatbelt tensioner 24a to a sill of the vehicle body structure 14 using fasteners (e.g., bolts, screws, rivets).In some embodiments, another robot (not shown) can assist in coupling the belt tensioner 24a to the vehicle body structure 14, or the belt tensioner 24a can be manually coupled to the vehicle body structure 14 via the fastening means. At 316, the control algorithm instructs the robot 26, using the controller 30, to grasp or pick up the second vehicle component 12b of vehicle component 12 using the end effector 26b. The second vehicle component 12b may be located on a rack or storage area that prevents movement of the second vehicle component 12b before it is picked up by the robot 26. At 320, the control algorithm instructs the robot 26, using the controller 30, to move the second vehicle component 12b in a desired pattern such that a section 78 (e.g., a rigid anchor) of the safety belt 24 is picked up in an opening or slot 76 (the slot 76 is shown enlarged in the figures for clarity) in the second vehicle component 12b.This means that, by moving the second vehicle component 12b, the section 78 of the safety belt 24 is guided through the opening in a lower section of the second vehicle component 12b (Figs. 6B and 6C). The opening 76 in the lower section of the second vehicle component 12b can be arc-shaped or extend in several directions such that a first end of the opening 76 is open through a first side of the second vehicle component 12b and a second end of the opening 76 is located between the first side and a second side of the second vehicle component 12b. As soon as the section of the safety belt 24 is positioned at or near the second end of the opening 76, the second vehicle component 12b and the safety belt 24 are coupled to each other.It is understood that when the robot 26 guides section 78 of the safety belt 24 through opening 76, the robot 28 can grasp or grip the webbing 24b of the safety belt 24 and pull the webbing 24b away from the second vehicle component 12b. In this way, entanglement between the second vehicle component 12b and the webbing 24b is prevented. At 324, the control algorithm instructs the robot 26, using the controller 30, to couple the second vehicle component 12b to the vehicle column 16 of the vehicle body structure 14 (Fig. 6D). In the illustrated example, the second vehicle component 12b is coupled to a lower section of the vehicle column 16 by a snap fastener, fastening device, or any other suitable attachment method. In some embodiments, the second vehicle component 12b may be coupled to a midpoint or another location of the vehicle column 16. In some embodiments, coupling the second vehicle component 12b to the vehicle column 16 includes coupling the second vehicle component 12b to the first vehicle component 12a. Unless expressly stated otherwise in this document, all numerical values ​​indicating mechanical / thermal properties, percentages of compositions, dimensions and / or tolerances, or other parameters are to be understood as modified by the word "approximately" or "about" when describing the scope of this disclosure. This modification is desirable for various reasons, including industrial practice, material, manufacturing and assembly tolerances, and testability. As used in this document, the phrase "at least one of A, B and C" should be interpreted as meaning a logical (A OR B OR C) using a non-exclusive logical OR, and should not be interpreted as meaning "at least one of A, at least one of B and at least one of C". In this application, the terms "controller" and / or "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 combinable logic circuit; a field-programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores 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, such as in a system-on-a-chip. The term storage is a subset of the term computer-readable medium. The term computer-readable medium, as used here, does not include transitory electrical or electromagnetic signals that propagate through a medium (such as via a carrier wave); the term computer-readable medium can therefore be considered tangible and non-transient.Non-restrictive examples of a non-transitory, tangible, computer-readable medium include non-volatile memory circuits (such as a flash memory circuit, a 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). The devices and procedures described in this application can be implemented in whole or in part by a specialized 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 translated into computer programs through the routine work of an experienced technician or programmer. The description of the revelation is purely exemplary, and thus it is intended that examples which do not deviate from the content of the revelation fall within its scope. Such variations are not to be considered a deviation from the nature and scope of the revelation. According to the present invention, a robot gripper device is provided for coupling to a first vehicle component, wherein the robot gripper device comprises: a first end effector comprising: a frame; a plurality of grippers mounted on the frame and configured to grasp the first vehicle component; and a plurality of molds mounted on the frame and configured to align the first vehicle component with respect to the first end effector, wherein each mold of the plurality of molds has a shape corresponding to a shape of the first vehicle component, one mold of the plurality of molds has a first rigidity and is a lattice mold with a plurality of openings, another mold of the plurality of molds is spaced apart from the first mold and has a second rigidity greater than the first rigidity. According to one embodiment, the multitude of grippers are vacuum grippers. According to one embodiment, each mold of the plurality of molds includes a body and end sections, wherein the end sections taper inwards towards the body. According to one embodiment, the following applies: The frame comprises a main frame and a first and a second frame element, which are spaced apart from each other and extend from the main frame; the plurality of grippers comprises a first gripper mounted on the first frame element and a second gripper mounted on the second frame element; one mold is mounted on the first frame element; and the other mold is mounted on the second frame element. According to one embodiment, the invention is further characterized by a retention feature which is mounted on one of the first and second frame elements and is configured to couple a second vehicle component to the first end effector. According to one embodiment, the invention is further characterized by the following: a second end effector comprising: a pair of opposing grippers that is movable between a first position in which the pair of opposing grippers engages a second vehicle component and a second position in which the pair of opposing grippers is released from the second vehicle component; and a mounting feature coupled to one of the opposing grippers and configured to grip the second vehicle component independently of the pair of opposing grippers. According to one embodiment, the mounting feature includes one or more magnets that are at least partially arranged therein. According to one embodiment, the invention is further characterized by the following: a controller that communicates with the second end effector and is configured to: instruct the second end effector to grasp the second vehicle component using the pair of opposing grippers; instruct the second end effector to move the second vehicle component to the first end effector and to place the second vehicle component at the restraint feature; and instruct the second end effector to grasp the second vehicle component using the mounting feature and to remove the vehicle component from the restraint feature. According to one embodiment, the invention is further characterized by a robot arm, wherein the frame is coupled to one end of the robot arm.

Claims

A robot gripper device for coupling to a first vehicle component, wherein the robot gripper device comprises: a first end effector comprising: a frame; at least one gripper mounted on the frame and configured to grasp the first vehicle component; and a first mold mounted on the frame and configured to align the first vehicle component with respect to the first end effector, wherein the first mold is made of an elastomeric material and has a shape corresponding to a shape of the first vehicle component. Robot gripper device according to claim 1, wherein the at least one gripper is a vacuum gripper. Robot gripper device according to claim 1, wherein the at least one gripper comprises a plurality of grippers mounted on different sections of the frame. Robot gripper device according to claim 1, wherein the first mold is a lattice mold comprising a plurality of openings. Robot gripper device according to claim 1, wherein the first mold includes a body and end sections and wherein the end sections taper inwards towards the body. Robot gripper device according to claim 1, wherein: the frame comprises a main frame and a first and a second frame element spaced apart from each other and extending from the main frame; the at least one gripper comprises a first gripper mounted on the first frame element and a second gripper mounted on the second frame element; the first mold is mounted on the first frame element; and a second mold is mounted on the second frame element and configured to further align the first vehicle component with respect to the first end effector, wherein the second mold has a shape corresponding to the shape of the first vehicle component and has a rigidity greater than the rigidity of the first mold. Robot gripper device according to claim 6, further comprising a restraint feature mounted on one of the first and second frame elements and configured to couple a second vehicle component to the first end effector. Robot gripper device according to claim 7, further comprising: a controller which communicates with the second end effector and is configured to: instruct the second end effector to grasp the second vehicle component using the pair of opposing grippers; instruct the second end effector to move the second vehicle component to the first end effector and to position the second vehicle component at the restraint feature; and instruct the second end effector to grasp the second vehicle component using the mounting feature and to remove the vehicle component from the restraint feature. Robot gripper device according to claim 6, further comprising: a second end effector, comprising: a pair of opposing grippers that is movable between a first position in which the pair of opposing grippers engages a second vehicle component and a second position in which the pair of opposing grippers is released from the second vehicle component; and a mounting feature that is coupled to one of the opposing grippers and configured to grip the second vehicle component independently of the pair of opposing grippers. Robot gripper device according to claim 9, wherein the mounting feature includes one or more magnets which are at least partially arranged therein. Robot gripper device according to claim 1, further comprising: a second end effector, comprising: a pair of opposing grippers that is movable between a first position in which the pair of opposing grippers engages a second vehicle component and a second position in which the pair of opposing grippers is released from the second vehicle component; and a mounting feature coupled to one of the opposing grippers and configured to grip the second vehicle component independently of the pair of opposing grippers. Robot gripper device according to claim 1, further comprising a robot arm, wherein the frame is coupled to an end of the robot arm.

Images