SETTING TOOL FOR EXPANSION NUTS, PLUGS AND THE LIKE

Description

[0001] The invention relates to a setting tool for expanding nuts, plugs, and the like, which is particularly suitable for automotive manufacturing. The setting tool comprises a magazine with a plurality of holders for parts to be set, a setting cylinder, a drive for the magazine, a drive for the setting cylinder, a vacuum terminal, and a control system for controlling the individual components of the setting tool.

[0002] Component placement processes are essential in assembly during series production, for example in the automotive industry. Numerous methods and devices have therefore been developed to make these processes cost-effective and efficient. Industrial robots with appropriate tools are frequently used. Precision and reliability are particularly important in automotive manufacturing to prevent costly rework. Special techniques have been developed for placing expansion nuts, plugs, and similar components in automotive manufacturing.

[0003] From DE 10 2005 041 679 A1, a setting tool according to the preamble of claim 1 and a method for automatically setting expansion nuts and / or sleeves in anchoring structures are known, in which the parts to be installed are held in a parts reservoir and transferred with the parts reservoir into a setting device before being automatically set. A disadvantage of this method is the large number of steps and movements that a setting tool must perform when setting the components. This is time-consuming.

[0004] It is important to note that in automotive assembly, car bodies are transported to their respective processing positions via an electric overhead conveyor. During this process, the anchoring positions can shift by a few millimeters. Such a deviation from the standard position poses a problem for positioning parts using robots.

[0005] The main disadvantage is the need for employees to determine the location of a missing component, which leads to delays in automated assembly. Furthermore, the missing components must be placed manually, which is performed on the underside of a vehicle body in an ergonomically awkward position. Greater precision in the placement process would result in a significant improvement.

[0006] The object of the invention is to provide a device and a system for limiting the number of steps and movements and for increasing the precision and reliability of placing components, in particular expanding nuts, plugs and the like, on the underside of car bodies using assembly robots. Furthermore, it would be desirable to have an automatic monitoring system that could increase the precision of placing such components.

[0007] This problem is solved by a setting tool with the features of claim 1, wherein the magazine is a revolver magazine, in the magazine receptacles, piston rods that can be pressurized with vacuum are arranged, each having a driver, wherein the setting cylinder can engage with a distally arranged driver element in a receptacle of the driver of the respective actuated piston rod in order to bring the respective piston rod into the setting position, and that the piston rods are equipped with vacuum heads suitable for sucking in, holding and releasing the parts to be set.

[0008] In particular, the setting tool according to the invention is arranged on the arm of an assembly robot which is suitable for bringing the setting tool into the desired assembly position.

[0009] The setting tool according to the invention has a magazine for the components to be set, which, unlike the prior art cited above, is permanently integrated into the setting tool and does not need to be mounted. The magazine is designed as a turret magazine, i.e., it can be rotated about its axis to bring the individual magazine positions into the setting position. The turret magazine is advantageously driven by an electric stepper motor. The number of magazine positions generally depends on the application. A number in the range of 8 to 24, and in particular 12 to 20, has proven to be practical.

[0010] Within the revolver magazine, which is conveniently cylindrical, piston rods are arranged, each with a centrally directed driver distal to the rod. These rods are used to insert the components. The hollow piston rods are connected to the vacuum terminal and can be individually vacuum-charged. A vacuum head located distally on each piston rod serves to draw in, hold, and release the desired component during the insertion process. It is understood that various components, such as expanding nuts and plugs, can be held by the vacuum heads and positioned accordingly during the insertion procedure. The necessary seals for maintaining the vacuum are integrated into the receptacles.

[0011] In particular, the piston rods of the turret magazine, with their vacuum heads, are suitable for suctioning the respective components from a prepared, separate magazine disk. The arrangement of the components in the magazine disk corresponds to the position of the piston rods in the turret magazine. To pick up the components, the robot arm moves the insertion tool into the suction position. The piston rods from the turret magazine are returned to their starting position, suctioning the components, after which the robot arm is retracted to the assembly position. The vacuum heads are preferably interchangeable to adapt them to the requirements of the respective component.

[0012] At the center of the revolver magazine is a setting cylinder with a drive element that engages the driver of a piston rod. The setting cylinder remains in its central position and does not rotate with the magazine. As the magazine rotates, each individual magazine position, with its piston rod, is moved into the setting position. The setting cylinder then engages the driver of the piston rod, extending the rod and placing the component. For placement, the piston rod is brought to normal pressure. After the component is placed, the setting cylinder retracts the piston rod, releasing the driver, which then returns to its starting position. Rotation of the magazine then moves the piston rod of the next magazine position into the setting position.The precise placement of the setting tool is achieved via the robot arm.

[0013] The drive element can be any component suitable for engaging with the piston rod's follower. The follower has a recess that slides over the drive element as the revolver magazine rotates. Suitable drive elements include, for example, brackets, but especially rollers that are dimensioned to fit the recess.

[0014] It goes without saying that the magazine positions can be processed sequentially or alternately, depending on which component is needed and available in the next magazine. The advantage is that the movement of the setting tool can be optimized and kept short.

[0015] The related revolver magazine according to the invention preferably has a cylindrical shape with receptacles for the piston rods, which are arranged along the periphery. The individual receptacles with the piston rods can be individually pressurized with a vacuum. The revolver magazine can be driven pneumatically or electrically; preferably, it is driven by an electric stepper motor.

[0016] The revolver magazine is housed in a casing that incorporates connections for vacuum lines to the individual cartridge slots. To apply a vacuum to each slot, individual vacuum channels, sealed against each other, are located between the revolver magazine and the casing. These vacuum channels conveniently run parallel around the circumference and terminate at openings leading into the individual cartridge slots. Each slot has its own dedicated vacuum channel. An outer casing protects this assembly.

[0017] The setting cylinder is located inside the turret magazine and has a drive element that points towards the periphery of the magazine. The setting cylinder does not rotate with the magazine; that is, it always points in the same direction. After extending, it actuates the piston rod and its attached component via the drive element. After the component is set, the setting cylinder retracts, and the turret magazine rotates to bring the next cartridges, with their piston rods and components, into the setting position. The setting cylinder is conveniently driven by compressed air.

[0018] According to a preferred embodiment, the setting tool according to the invention has a camera unit on the outer casing of the turret magazine. This camera unit is intended to determine the center point of the assembly or anchoring position on a car body before each setting operation and to calculate any deviation from the predetermined center point of the anchoring position. If the deviation is too large, the robot must be repositioned, otherwise correct component assembly cannot take place. Excessive deviation from the reference position can occur, for example, due to sloppy work in previous work steps in car body construction or due to inaccurate guidance of the car body in the processing station. Preferably, the camera unit is arranged on the casing of the turret magazine at the level of the setting position. Additionally, a lighting element can be arranged on the outer casing.

[0019] The setting tool according to the invention is, in particular, mounted on the arm of an assembly robot, such as those used, for example, in the automotive industry. For instance, up to four such assembly robots can be used in the corresponding processing station for setting expansion nuts, plugs, and the like. Accordingly, the invention also relates to a combination of an assembly robot and the setting tool described above.

[0020] Furthermore, the invention relates to a system comprising a combination of an assembly robot and a placement tool according to the invention, as well as a separate magazine disc with receptacles for the components to be placed, which are drawn in by the piston rods arranged in the receptacles of the turret magazine. Such a separate magazine disc is refilled each time the assembly robot places the components in a vehicle body. It is understood that the components in the separate magazine disc have the same arrangement as after being picked up by the turret magazine.

[0021] It is further understood that the setting tool according to the invention, as well as the combination of setting tool and assembly robot and the system of setting tool, assembly router and magazine disc, have the necessary control devices to perform their assigned tasks. In particular, this requires the timing of the individual steps and movements. Such control systems and the software required for them are familiar to those skilled in the art.

[0022] The invention is explained in more detail by the accompanying illustrations.

[0023] In a preferred embodiment, they show Figure 1 a setting tool according to the invention in overall view; Figure 2 the setting unit of the setting tool according to Figure 1 ; Figure 3 the revolver magazine of the setting unit according to Figure 2 ; Figure 4 a piston rod with vacuum head; Figure 5 the setting cylinder of a setting tool according to the invention; Figure 6the setting tool according to the invention mounted on a robot arm; and Figure 7 Combinations of vacuum heads and components.

[0024] Figure 1Figure 1 shows an overall view of the setting tool 1 according to the invention, including the turret magazine 2 and the piston rods 3 arranged peripherally and at regular intervals in receptacles therein, with attached vacuum heads 4 and components 5. The turret magazine 2 is driven by a stepper motor (not shown) such that the piston rods 3 are moved into the desired setting position. The stationary setting cylinder 6 is located in the center of the turret magazine 2, shown in conjunction with an extended piston rod 3 in the setting position. The turret magazine 2 is surrounded by an outer casing 7, on the front of which a camera 8 is arranged, which does not rotate with the turret magazine 2. The camera 8 is positioned so that it is focused on the mounting position of the piston rod 3 in the setting position.A vacuum terminal 9 is connected to vacuum ports 10 via vacuum hoses (not shown) and supplies the receptacles and piston rods 3 with individually controllable negative pressure. The setting tool 1 is mounted on a carrier plate 11, which in turn is mounted on the arm of an assembly robot. According to a preferred embodiment, the setting tool 1 according to the invention has sixteen receptacles with 16 piston rods 3 arranged therein.

[0025] Figure 2Figure 1 shows a sectional view of the revolver magazine 2 without the casing 7. At the center of the revolver magazine 2 is the setting cylinder 6, which has a drive element 13 in the form of a roller at the end of its push rod 12. The roller 13 engages in a recess 14 of the driver 15 of a piston rod 3. The setting cylinder 6 and the piston rod 3 are shown in the extended position. Extending the piston rod sets the respective component. The piston rod 3 is arranged in a receptacle 16 of the revolver magazine 2. Further receptacles 16 and piston rods 3 are arranged at the periphery of the revolver magazine 2; the vacuum heads 17 are shown of the piston rods 3 located behind the sectional plane.

[0026] The revolver magazine 2 has a toothed ring 18 at its upper end, which is driven by a preferably electric stepper motor via a toothed belt (not shown). The stepper motor is suitable for rotating the individual piston rods into the set position. This can be done either sequentially or in any desired order.

[0027] Vacuum channels 19 are arranged around the periphery of the revolver magazine 2; in the illustrated case, sixteen mutually separated and sealed channels for a total of sixteen receptacles 16 with their piston rods 3 arranged therein. Each receptacle 16 is connected to a corresponding vacuum channel 19 via an outwardly facing opening in its wall. The vacuum channels 19 are themselves part of a jacket 20 that surrounds the revolver magazine 2. The jacket 20 does not participate in the rotation of the revolver magazine 2.

[0028] The individual vacuum channels 19 are connected to the vacuum terminal 9 via hose connections (not shown) ( Figure 1 They are connected. They run parallel to each other around the circumference.

[0029] Figure 3 Figure 1 shows the actual revolver magazine 2 with the toothed ring 18 at the upper end and the openings 29 for connecting the receptacles 16 to the vacuum ports 10. The magazine is divided into an upper and a lower half. The openings 29 correspond to the vacuum channels 19, which run between the jacket 20 and the revolver magazine 2.

[0030] Figure 4Figure 1 shows a piston rod 3 related to the invention. The piston rod 3 is a hollow profile, in particular a simple tube, which terminates in a profiled end 21 onto which the vacuum head 17 is mounted. A driver 15 is screwed on laterally – the screw heads 22 are shown – and a receptacle 14 is located centrally, into which the drive element 13 of the setting cylinder 6 engages. The vacuum heads 17 are preferably secured by threaded pins.

[0031] Figure 5Figure 1 shows a related setting cylinder 6 according to the invention, which is rotatably fixed to a bracket 22 projecting into the center of the revolver magazine 2 at the pivot joint 23. The setting cylinder 6 has a push rod 12 distal to the bracket, which terminates in the drive roller 13. The drive roller 13 itself is rotatably connected to the push rod 12 via the pivot joint 24 and is held in position by the arm 25, which is pivotally connected to the bracket 22. The setting cylinder 6 is operated with compressed air via the connections 26 and 27.

[0032] The setting cylinder 6 and the piston rods 3 are designed to be compatible such that, during rotation of the revolver magazine 2, the drivers 15 of the piston rods 3 engage the drive element 13 of the setting cylinder 6 in their receptacle 14 and are released again after the setting process. During the setting process, the drive element 13 of the setting cylinder 6 remains engaged in the receptacle 14 and follows the downward / upward movement of the push rod 12.

[0033] Figure 6Figure 30 shows a typical assembly robot 30, as used in the automotive body assembly industry, with a setting tool 1 mounted on the arm 31 by means of a carrier plate 11. The setting tool 1 can be guided under the body of a vehicle by the robot arm and place the components held by the vacuum heads onto the respective body. During the setting process, the respective piston rod 3 is disconnected from the vacuum so that the component is released, and the component is pressed into the body opening to be fitted by means of the setting cylinder 6. The components that have not yet been set remain connected to their vacuum lines. After all components have been set, the setting tool 1 is moved by the assembly robot 30 to a magazine disk that holds new components for the setting tool 1. These new components are again drawn in by vacuum for the next setting cycle.

[0034] Figure 7Figure 1 shows different variants of vacuum heads 17 for the respective components to be attached. The vacuum heads 17 are secured to the profiled end 21 of a piston rod 3 by a threaded pin; the bore 32 for the threaded pin is shown.

[0035] Figure 7A shows the vacuum head 17 together with an expansion dowel 33, Figure 7B together with another variant of an expansion dowel 34. Figure 7C and 7D Figure 1 shows variants of a vacuum head 17 together with an elongated plug 35 and a round plug 36.

[0036] The setting tool according to the invention can be used not only in the automotive industry for the automatic setting of a large number of components, but also generally in the series production of technical products.

[0037] Experts are familiar with the coordination and control of such automated assembly processes. Suitable programs are available or can easily be created by an expert.

Claims

1. Setting tool for expanding nuts, plugs and the like, in particular for automotive construction, having - a magazine (2) with a plurality of receptacles (16) for the parts (33, 34, 35, 36) to be set, - a setting cylinder (6), - a drive for the magazine, - a drive for the setting cylinder (6), - a vacuum terminal (9), - a control system for controlling the individual components of the setting tool (1), characterised in that the magazine (2) is a revolver magazine and piston rods (3) that can be subjected to vacuum are arranged in the receptacles (16) of the magazine and each have a driver (15), wherein the setting cylinder (6) can engage with a distally arranged driving element (13) in a receptacle (14) of the driver (15) of the respectively actuated piston rod (3) in order to bring the respective piston rod (3) into the setting position, and in that the piston rods (3) are provided with vacuum heads (17) that are suitable for suctioning up and holding the parts (33, 34, 35, 36) to be set and releasing them during setting.

2. Setting tool according to claim 1, characterised in that the revolver magazine (2) has a cylindrical shape and can be driven by an electric stepper motor.

3. Setting tool according to claim 1 or 2, characterised in that the receptacles (16) of the revolver magazine (2) in which the piston rods (3) are held are arranged peripherally, wherein the individual receptacles (16) can be individually subjected to vacuum.

4. Setting tool according to any one of the preceding claims, characterised in that the revolver magazine (2) is held in a casing (20) that has vacuum lines (19) to the individual receptacles (16), wherein the vacuum lines (19) between the revolver magazine (2) and the casing (20) are parallel vacuum channels.

5. Setting tool according to claim 4, characterised in that the vacuum channels (19) are delimited and sealed from each other.

6. Setting tool according to any one of the preceding claims, characterised in that the setting cylinder (6) is arranged within the revolver magazine (2).

7. Setting tool according to any one of the preceding claims, characterised in that the setting cylinder (6) is connected to a compressed air system.

8. Setting tool according to any one of the preceding claims, characterised in that the driving element (13) of the setting cylinder (6) is a movable roller that can engage in the recess (14) of the driver (15) of each piston rod (3).

9. Setting tool according to any one of the preceding claims, characterised in that the vacuum heads (21) of the piston rods (3) are interchangeable and adapted to the shape of the respective part (33, 34, 35, 36) to be set.

10. Setting tool according to any one of the preceding claims, characterised by a camera unit (8) on the outer casing (7) of the revolver magazine (2) for detecting the centre of the assembly position of the part (33, 34, 35, 36) to be set and, if necessary, for controlling the setting process.

11. Setting tool according to one of the preceding claims, mounted on the arm (31) of an assembly robot (30).

12. Assembly robot having a setting tool according to any one of claims 1 to 11.

13. System consisting of an assembly robot (30) according to claim 12 and a separate magazine disc having receptacles for the parts (33, 34, 35, 36) to be set, from which the setting tool (1) suctions up the parts (33, 34, 35, 36) by means of the vacuum heads (21) of the piston rods.