Automatic Loading Station

Abstract

An automatic fastener driving tool with an automatic side-loading magazine can be automatically loaded with fasteners via a high-volume automatic loading station. The tool and magazine move proximate to the loading station. The magazine door automatically opens, and the loading station pushes fasteners into the magazine. The magazine door automatically closes, and the tool and magazine return to their original positions.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 406,177, entitled "AUTOMATIC STAPLE LOADING STATION," filed September 13, 2022. [Technical Field]

[0002] The technology disclosed herein relates generally to fastener driving tools, and specifically to an automatic fastener driving tool having an automatic side-loading magazine capable of automatic loading via an automatic fastener loading station. An embodiment is specifically disclosed as an automatic fastener loading station mounted proximate to an assembly line including a robotically controlled automatic fastener driving tool, where the robot moves the fastener driving tool proximate the automatic fastener loading station, which can then load fasteners into the automatic side-loading magazine of the automatic fastener driving tool.

[0003] Statement on Federally Sponsored Research and Development none. [Background technology]

[0004] To improve efficiency on assembly lines, robotically operated automated fastener driving tools are used. These tools are typically pneumatically driven and include magazines that contain hundreds of fasteners. However, when the tool's magazine becomes empty during normal operation, a human user must typically reload the magazine with a new load of fasteners, after which the tool can continue normal operation. Some conventional magazines allow for the reloading of several cartridges of fasteners to fill the magazine.

[0005] The magazine loading station typically holds individual fastener cartridges, each consisting of multiple fasteners stacked near the assembly line for easy access by a human user. The fastener cartridges may even be stored in packaging material at the manufacturing facility. A human user typically must manually open and align the fastener cartridges before loading them into the tool's magazine. Summary of the Invention

[0006] It would therefore be advantageous to provide an automated fastener driving tool that includes a robotic workstation and a connection to a high-speed communications network (e.g., the Internet), and has a sensor capable of measuring the length of a strip of fasteners loaded in an associated magazine, the automated sensor also being able to determine whether at least one strip of fasteners remains in the magazine and whether the tool has fired a fastener.

[0007] Another advantage is to provide an automatic side-loading magazine for a robotically controlled fastener driving tool that includes a clamping subassembly (“S / A”) that holds fasteners in place within the magazine, where the fasteners may be of various lengths, and where the magazine is operable to be automatically loaded via a high-capacity loading station.

[0008] Yet another advantage is the provision of a high-capacity automated fastener loading station that can store and dispense thousands of fasteners during normal operation, where a human user only needs to initially load the station during normal operation, and the fasteners will be automatically repositioned for exit and dispensed to robotically controlled fastener driving tools until the loading station is empty.

[0009] Yet another advantage is the provision of an automatic side-loading magazine for a robotically controlled fastener driving tool that includes a clamping subassembly that pushes a cartridge containing a plurality of fastener strips to one side of the magazine.

[0010] A further advantage is the provision of an automatic side-loading magazine for a robotically controlled fastener driving tool that includes a clamping subassembly that urges a cartridge containing multiple fastener strips up onto the working strip.

[0011] A still further advantage is the provision of an automated loading station having a chain drive that sequentially moves multiple carriers holding fasteners so that each carrier can automatically dispense its fasteners for loading into a magazine for a robotically controlled fastener driving tool.

[0012] Yet a further advantage is to provide an automatic loading station having a chain drive that sequentially moves a plurality of carriers holding fasteners, the chain drive including two separate chains, each chain holding a single carrier, each pair of single carriers being at substantially the same height as each other, such that each chain is mechanically operable to rotate so that each pair of single carriers is operable to hold a plurality of fasteners.

[0013] Another advantage is to provide an automated loading station having at least one chain drive that sequentially moves a plurality of carriers holding fasteners, the chain drive including at least one sun gear and at least one planetary gear, such that the plurality of carriers are operable to move parallel (horizontally) to one another as each carrier moves around the at least one sun gear and its corresponding ring gear.

[0014] Yet another advantage is to provide an automatic loading station having a loading arm that includes a dual telescoping section that presents two separate, ultra-thin slide sections, such that the loading arm can extend far enough to push a cartridge of fasteners into a magazine of an automatic fastener driving tool.

[0015] Yet another advantage is to provide an automatic fastener driving tool with a side-loading magazine, where the magazine includes a door that can be opened to receive a cartridge of fasteners, and then the door can be closed so that the tool can be manipulated in any orientation in a three-dimensional work environment while the fastener cartridge is securely seated in the magazine.

[0016] Additional advantages and other novel features will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the techniques disclosed herein.

[0017] To achieve the foregoing and other advantages, according to one aspect, an automated fastener loading machine is provided, the automated fastener loading machine comprising: an outer housing including an entrance loading portion, a main retention portion, and a dispensing outlet portion, the entrance loading portion having a first opening sized and shaped to receive at least one cartridge, the at least one cartridge including a plurality of fasteners, the main retention portion sized and shaped to accommodate a plurality of the at least one cartridge, and the dispensing outlet portion having a second opening sized and shaped to dispense the at least one cartridge; (a) the outer housing at least partially encloses a plurality of movable shelves, each sized and shaped to hold at least one cartridge; (b) the plurality of movable shelves are connected to a drive system that moves the movable shelves from the entrance loading portion to the dispensing outlet portion while having the capability of carrying the at least one cartridge; and (c) when one of the plurality of movable shelves reaches the dispensing outlet portion, the drive system allows the at least one cartridge to be moved through the second opening, thereby allowing it to be unloaded from the automated fastener loading machine.

[0018] According to another aspect, there is provided an automated magazine for a fastener driving tool, the automated magazine comprising: a cover portion including a pivotable door; a receiving portion for receiving a cartridge through the pivotable door in an open position; an exit portion including an exit opening proximal to a guide body of the fastener driving tool; and a clamp attached to the pivotable door, the clamp biasing the cartridge toward one side of the magazine proximal to the exit opening, the cartridge comprising a plurality of fastener strips arranged next to each other with the fasteners facing downward, the cartridge presenting a lead strip of fasteners arranged to be subsequently loaded into the guide body, the lead strip of fasteners being biased upward toward the exit opening regardless of the length of the fasteners in the lead strip, the pivotable door controlled by an actuator to remain closed except when a cartridge is loaded into the receiving portion.

[0019] According to a further aspect, there is provided a magazine for use with a fastener driving tool, the magazine comprising: a cover portion including a pivotable door; a receiving portion for receiving a cartridge through the pivotable door in an open position; an exit portion including an exit opening proximal to a guide body of the fastener driving tool; and a clamp attached to the pivotable door, the clamp including a plurality of removably attachable plates for supporting the cartridge, the cartridge comprising a plurality of fastener strips arranged adjacent to one another with the fasteners facing downward, the cartridge presenting a lead strip of a fastener arranged to be subsequently loaded into the guide body, the lead strip of the fastener being biased upward toward the exit opening regardless of the length of the fastener within the lead strip.

[0020] According to still further aspects, an automated fastener loader is provided, the automated fastener loader comprising: an outer housing including an inlet loading portion, a main retention portion, and a dispensing outlet portion, the inlet loading portion having a first opening sized and shaped to receive at least one cartridge, the at least one cartridge including a plurality of fasteners, the main retention portion being sized and shaped to accommodate a plurality of the at least one cartridge, and the dispensing outlet portion having a second opening sized and shaped to dispense the at least one cartridge; a motor in mechanical communication with at least one chain drive, the at least one chain drive including a continuous chain; a first plurality of movable carriers and an opposing second plurality of movable carriers, the first plurality of movable carriers and the second plurality of movable carriers not contacting each other and defining an open space therebetween. the first and second plurality of movable carriers are connected in pairs to a continuous chain of at least one chain drive, whereby each of the first plurality of movable carriers faces each of the second plurality of movable carriers, the chain drive is operable to move the pair of movable carriers from the entrance loading section to the dispensing outlet section while each of the pair of movable carriers carries at least one cartridge, and when one of the pair of movable carriers reaches the dispensing outlet section, the chain drive allows the at least one cartridge to be moved through the second opening, thereby allowing it to be unloaded from the automatic fastener loader; and an outer housing at least partially encloses the first and second plurality of movable carriers and the at least one chain drive.

[0021] According to yet a further aspect, a method for dispensing fasteners from an automated loading station is provided, the method comprising: (a) providing an automated loading station, the automated loading station comprising: (i) an outer housing including an entrance loading portion, a main holding portion, and a dispensing outlet portion, the entrance loading portion having a first opening sized and shaped to receive at least one cartridge, the at least one cartridge including a plurality of fasteners, the main holding portion being sized and shaped to accommodate a plurality of the at least one cartridge, and the dispensing outlet portion having a second opening sized and shaped to dispense the at least one cartridge; (ii) a motor in mechanical communication with at least one chain drive; and (iii) a first plurality of movable carriers and an opposing second plurality of movable carriers at least partially enclosed by the outer housing, the first plurality of movable carriers and the second plurality of movable carriers being out of contact with each other and exhibiting an open space therebetween, the first plurality of movable carriers and the second plurality of movable carriers being spaced apart from each other; (b) moving the pairs of movable carriers from an entrance loading portion to a dispensing exit portion using the chain drive; (c) loading at least one cartridge from one of the pairs of movable carriers onto a loading arm; (d) providing an automatic magazine for use with a fastener driving tool, the magazine comprising: (i) a cover portion including a pivotable door; (ii) a receiving portion that receives at least one cartridge through the pivotable door in an open position; (iii) an exit portion that includes an exit opening proximal to a guide body of the fastener driving tool; and (iv) a clamp mounted on the pivotable door, the clamp including a plurality of removably attachable plates that support at least one cartridge; and (e) opening the pivotable door of the magazine.(f) extending the loading arm from the dispensing outlet portion of the loading station toward the magazine; (g) loading at least one cartridge from the automatic loading station into the magazine; (h) retracting the loading arm away from the magazine to its original position; and (i) closing the pivotable magazine door.

[0022] Still other advantages will become apparent to those skilled in the art from the following description and drawings, in which a preferred embodiment in one of the best modes contemplated for carrying out the present technology is described and shown. As will be understood, the technology disclosed herein is capable of other and different embodiments, and its several details are capable of modification in various obvious aspects, all without departing from the principles thereof. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature and not restrictive. [Brief explanation of the drawings]

[0023] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the technology disclosed herein and, together with the description and claims, serve to explain the principles of the technology.

[0024] [Figure 1] FIG. 1 is a front left perspective view of an automatic fastener driving tool having an automatic side-loading magazine constructed in accordance with the principles of the technology disclosed herein;

[0025] [Figure 2] FIG. 2 is a rear left perspective view of the tool and magazine of FIG. 1;

[0026] [Figure 3] FIG. 2 is a left side elevational view of the tool and magazine of FIG. 1.

[0027] [Figure 4] FIG. 2 is a rear elevational view of the tool and magazine of FIG. 1.

[0028] [Figure 5] FIG. 1 is a front left perspective view of a high volume automated fastener loading station constructed in accordance with the principles of the technology disclosed herein;

[0029] [Figure 6] 6 is a perspective view showing a first stage of a fastener loading sequence between the tool and magazine of FIG. 1 and the loading station of FIG. 5. FIG.

[0030] [Figure 7] FIG. 7 is a perspective view showing a second stage of the fastener loading sequence of FIG. 6.

[0031] [Figure 8] FIG. 7 is an elevational view showing a third stage of the fastener loading sequence of FIG. 6.

[0032] [Figure 9] FIG. 7 is an elevational view showing a fourth stage of the fastener loading sequence of FIG. 6.

[0033] [Figure 10] FIG. 7 is a perspective view showing a fifth stage of the fastener loading sequence of FIG. 6.

[0034] [Figure 11] FIG. 7 is a perspective view showing a sixth stage of the fastener loading sequence of FIG. 6.

[0035] [Figure 12] FIG. 7 is a perspective view showing a seventh stage of the fastener loading sequence of FIG. 6.

[0036] [Figure 13] FIG. 8 is a perspective view showing an eighth stage of the fastener loading sequence of FIG. 7.

[0037] [Figure 14] 6 is a right-side perspective view showing the tool and magazine of FIG. 1 mounted on a robotic control station, the loading station of FIG. 5, and an example of a human user working on an assembly line.

[0038] [Figure 15] FIG. 15 is a left perspective view of FIG.

[0039] [Figure 16] 1 is a first alternative embodiment automatic fastener driving tool having an elongated magazine.

[0040] [Figure 17] 6 is a flow chart illustrating certain functions performed during a "fastener loading sequence" as used in the tool and magazine of FIG. 1 and the loading station of FIG. 5;

[0041] [Figure 18] FIG. 10 is a front left perspective view of a second alternative embodiment of a high volume automated fastener loading station constructed in accordance with the principles of the technology disclosed herein.

[0042] [Figure 19] FIG. 19 is a front left perspective view of the loading station of FIG. 18, with a portion of the outer housing not shown.

[0043] [Figure 20] FIG. 19 is a front left perspective view of the loading station of FIG. 18 showing some of the internal mechanical features.

[0044] [Figure 21] FIG. 19 is an enlarged view of the loading station of FIG. 18 showing some of the details of the fastener pusher and carrier.

[0045] [Figure 22] FIG. 19 is a left side elevational view of the loading station of FIG. 18 loaded with several cartridges of fasteners.

[0046] [Figure 23] FIG. 19 is an enlarged view of the loading station of FIG. 18 showing the cartridge magazine loaded onto the pusher.

[0047] [Figure 24] FIG. 19 is an enlarged view of the loading station of FIG. 18 showing the cartridge magazine extending outward on the pusher away from the loading station.

[0048] [Figure 25] FIG. 19 is a rear right-side perspective view of the loading station of FIG. 18.

[0049] [Figure 26] FIG. 10 is a front left perspective view of a third alternative embodiment of an automatic fastener driving tool having an automatic side-loading magazine constructed in accordance with the principles of the technology disclosed herein.

[0050] [Figure 27] FIG. 27 is an enlarged view of the tool of FIG. 26 showing certain details of the magazine.

[0051] [Figure 28] FIG. 27 is a left cutaway view of the tool of FIG. 26 showing the initial position of the loaded cartridge within the magazine.

[0052] [Figure 29] FIG. 27 is a left cutaway view of the tool of FIG. 26 showing the position of the cartridges in the magazine during operation of the tool after some of the fasteners have been driven.

[0053] [Figure 30] FIG. 19 is a left perspective view of the loading station of FIG. 18.

[0054] [Figure 31] FIG. 19 is a partial right-side perspective view of the loading station of FIG. 18, showing the motor portion.

[0055] [Figure 32] FIG. 19 is a partial left side elevational view of the loading station of FIG. 18 showing some of the carriers proximal to the lower gear.

[0056] [Figure 33] FIG. 33 is a cutaway view taken along line 33-33 of FIG. 32.

[0057] [Figure 34] FIG. 19 is a partial front elevational view of the loading station of FIG. 18, with some of the carriers contacting one of the lower gears.

[0058] [Figure 35] FIG. 35 is a cutaway view taken along line 35-35 of FIG. 34.

[0059] [Figure 36] FIG. 36 is a cutaway view taken along line 36-36 of FIG.

[0060] [Figure 37] FIG. 10 is a partial left side view of a fourth alternative embodiment of a high volume automated fastener loading station constructed in accordance with the principles of the technology disclosed herein.

[0061] [Figure 38] FIG. 38 is a partial left side view of the loading station of FIG. 37 showing the telescoping loading arm extended.

[0062] [Figure 39] FIG. 1 is a schematic block diagram of the major electrical components of an automated driving tool, a loading station, and an external controller constructed in accordance with the principles of the technology disclosed herein.

[0063] [Figure 40] FIG. 19 is a partial side cutaway view of the loading station of FIG. 18 showing the first lower main gear.

[0064] [Figure 41] FIG. 19 is a partial side cutaway view of the loading station of FIG. 18 showing the second upper main gear.

[0065] [Figure 42]FIG. 19 is a partial side cutaway view of the loading station of FIG. 18 showing the first upper main gear.

[0066] [Figure 43] 19 is a partial side cutaway view of the loading station of FIG. 18 showing a single carrier gear and carrier attached to one of the drive chains. DETAILED DESCRIPTION OF THE INVENTION

[0067] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like numerals refer to the same elements throughout.

[0068] It is to be understood that the technology disclosed herein is not limited in its application to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The technology disclosed herein is capable of other embodiments and of being practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having," and variations thereof, herein is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items. Unless otherwise limited, the terms "connected," "coupled," or "mounted," and variations thereof, herein are used broadly and include direct and indirect connections, couplings, or attachments. Furthermore, the terms "connected" or "coupled," and variations thereof, are not limited to physical or mechanical connections or couplings. Additionally, the terms "in communication with" or "in communication with" refer to two distinct physical or virtual elements passing signals or information between one another in some manner, whether the signal or information transmission is direct or whether there are additional physical or virtual elements between them that are also involved in the transmission of the signal or information. Additionally, the term "in communication with" can also refer to a mechanical, hydraulic, or pneumatic system in which one end of the "communication" (the "first end") can be the "cause" of a certain kinetic force (mechanical movement or hydraulic or pneumatic change of state) that occurs, and the other end of the "communication" (the "second end") can be "affected" by that movement / change of state, regardless of whether there are intermediate components between the "first end" and "second end."If a product has moving parts that depend on magnetic fields or somehow detects changes in magnetic fields, or if data is passed from one electronic device to another through the use of magnetic fields, then these situations can be referred to as being in "magnetic communication" with each other, where one end of the "communication" can induce a magnetic field and the other end can receive and be affected by (or otherwise affected by) that magnetic field.

[0069] The terms "first" or "second" preceding an element name, e.g., first inlet, second inlet, etc., are used for distinguishing purposes to distinguish among similar or related elements, results, or concepts and are not necessarily intended to denote order, nor are the terms "first" or "second" intended to exclude the inclusion of additional similar or related elements, results, or concepts, unless otherwise indicated.

[0070] Furthermore, although the embodiments disclosed herein may, for purposes of explanation, be shown and described as if most of the components were implemented solely in hardware, it should be understood that the embodiments disclosed herein include both hardware and electronic components or modules.

[0071] It will be understood that the term "circuitry," as used herein, can refer to an actual electronic circuit, such as an integrated circuit chip (or portion thereof), or can refer to a function performed by a processing circuit, such as a microprocessor or ASIC, that includes a logic state machine or another form of processing element (including sequential processing circuitry). A particular type of circuit may be some type of analog or digital circuit, although such circuitry may, in some cases, be implemented in software by a logic state machine or sequential processor. In other words, if a processing circuit is used to perform a desired function (such as a demodulation function) used in the technology disclosed herein, there may not be a specific "circuitry" that may be referred to as a "demodulation circuit," but rather there will be a demodulation "function" performed by software. All of these possibilities are contemplated by the inventors and are within the principles of the present technology when discussing "circuitry."

[0072] Referring now to FIG. 1, an automatic fastener driving tool, generally designated by reference numeral 10, includes an automatic side-loading magazine 30. Tool 10 exhibits an external gas connection 20, an integrated controller connection portion 22, a housing 24, a guide body 28, and a fastener exit end 26. Preferably, the tool is pneumatically operated, although power-operated tools are also contemplated. An exemplary tool is the SKSXP, a tool sold by Kyocera Senco Industrial Tools, Inc. and distributed by Kyocera Senco Europe.

[0073] The magazine 30 is attached to the tool 10 and includes a door 34, a cover portion 36, and a flexible or spring-loaded clamp S / A 40 to hold a plurality of fasteners 32 (such as staples). Preferably, the fasteners 32 are aligned into strips, several strips containing several hundred fasteners at a time, forming a sort of "cartridge." These fastener strips are positioned next to each other and face downward (i.e., in the same direction as the fastener exit end 26). The magazine 30 can hold a variety of fastener lengths, and the clamp S / A 40 holds the fasteners pressed in place against one side of the magazine.

[0074] The magazine 30 presents a receiving portion 38 into which the cartridges 32 are loaded through a pivotable door 34, which must be in the open position. The magazine 30 also presents an exit portion having an exit opening proximal to the guide body 28. The cartridges 32 present fastener lead strips that are then positioned for loading into the guide body 28 by clamps S / A 40, which also bias the lead strips upward toward the exit opening.

[0075] 2, there is shown an external pressurized gas connection 20 and an integrated controller connection 22. An external pressurized gas source is connected to the external gas connection 20 and powers the tool 10 during operation. The integrated controller connection 22 is operably connected to a robot control workstation 300 (see FIGS. 14-15 ), and the tool 10 is controlled through the workstation 300 via the integrated controller connection 22.

[0076] Tool 10 also includes a non-contact sensor (proximity sensor or other distance measuring sensor) and a linear measurement sensor. The non-contact sensor determines whether the magazine contains at least one aligned strip of fasteners loaded in magazine 30, while the linear measurement sensor determines whether at least one fastener 32 remains in magazine 30 and can determine whether tool 10 has fired a fastener 32. Both sensors are controlled by a "field logic controller" or "FLC" located on tool 10. Preferably, the FLC is connectable to a high-speed communications network such as the Internet or an internal intranet.

[0077] 3, in the illustrated embodiment, the housing 24 does not cover the magazine 30. The housing 24 primarily covers the internal mechanisms of the tool 10.

[0078] 4, in the illustrated embodiment, the external gas connection 20 and the integrated controller connection 22 are only partially covered by the housing 24. The magazine 30 is mounted to load at least one strip of fasteners in a direction perpendicular to the firing direction of the tool 10.

[0079] 5, there is shown a high-volume automated fastener loading station (or "loader") generally designated by reference numeral 200, which includes an outer housing 214, a vertical opening 212 in the outer housing, a (refill) inlet loading portion 210 (having the top opening of the housing), and a guide 220 in a dispensing outlet portion 216 of the housing (i.e., which is the outlet of the loader 200). The inlet loading portion 210 includes a first opening sized and shaped to receive at least one cartridge containing a plurality of fasteners. The dispensing outlet portion 216 includes a second opening sized and shaped to dispense at least one cartridge containing a plurality of fasteners.

[0080] The loading station 200 can hold several sets of fastener cartridges 32 (each cartridge containing hundreds of fasteners arranged in multiple individual elongated strips of fasteners) and can automatically dispense them into the magazine 30 of the tool 10, as described in more detail below. The loading station 200 is relatively tall in the embodiment shown, with most of its height consisting of its "main holding section," which is designed to accommodate many layers of fastener cartridges between its upper entrance loading section 210 and its lower dispensing exit section 216, where the fasteners exit the loading station.

[0081] In a typical manufacturing operation, a human user would manually load fastener cartridges 32 into station 200 via inlet refill section 210. These cartridges 32 are temporarily stored in station 200 until they are dispensed into tool magazines 30. Station 200 includes a chain drive with a movable shelf driven by a planetary gear set that automatically moves cartridges 32 from the top to the bottom of an opening in housing 212, where they then exit the station (and into tool magazines 30) via guides at a dispensing outlet section 216 of loader 200. Preferably, the planetary gear set has a ratio of 1.5:1 in this illustrated embodiment.

[0082] The structure and operation of the automated fastener loader 200 are summarized as follows: an outer housing at least partially encloses a plurality of movable shelves, each sized and shaped to hold at least one of a plurality of fastener-containing cartridges. The plurality of movable shelves are connected to a drive system that moves the movable shelves from an entrance loading section to a dispensing outlet section while being capable of transporting at least one of the plurality of fastener-containing cartridges. When one of the plurality of movable shelves reaches the dispensing outlet section, the drive system allows at least one of the cartridges to be moved through a second opening, thereby allowing it to be unloaded from the automated fastener loader. The drive system of the illustrated embodiment includes a continuous chain connected to the plurality of movable shelves that rotates within the loader to move each movable shelf from the entrance loading section to the dispensing outlet section and then back to the entrance loading section. As described above, the drive system uses a plurality of planetary gear sets that act as prime movers for the continuous chain.

[0083] Fastener Loading Sequence

[0084] Referring now to Figure 6, the first stage of the fastener loading sequence is shown. In this first stage, the robotic arm 302 (see Figure 15) automatically moves (using the robotic control workstation 300) the tool 10 to a position proximate the loading station 200. Next, in Figure 7, in the second stage of this loading sequence, the magazine door 34 is opened (preferably pneumatically). The magazine 30 is constructed to allow a clear path for the loading station 200 to load the magazine 30. Then, in Figure 8, in the third stage of the loading sequence, the tool 10 is moved into contact with the loading station 200.

[0085] 9, in the fourth stage of the loading sequence, the tool 10 is in contact with the loading station 200. At this stage, the guides at the outlet end of the loader 220 are positioned between the open magazine 30 and the clamp S / A 40.

[0086] 10, in the fifth stage of the loading sequence, the loading station 200 automatically moves the next nested fastener cartridge 32 downward (note that for clarity, the tool 10 is not shown). Then, in FIG. 11, in the sixth stage of the loading sequence, the loading station 200 pushes a single fastener cartridge 32 out the opening in the housing 212 and onto a guide at the exit end of the loader 220 (again, for clarity, the tool 10 is not shown). It should be noted that clamp S / A 40 is used to keep the fastener strip oriented correctly relative to one side of the magazine 30.

[0087] 12, in a seventh stage of the loading sequence, the tool 10 is moved out of contact with the loading station 200 (using the robotic control workstation 300) and the magazine door 34 is automatically (preferably pneumatically) closed. (Note that for clarity, station 200 is not shown.) In FIG. 12, the position of the tool 10 relative to station 200 is similar to that shown in FIG. 6. Finally, in FIG. 13, in an eighth stage of the loading sequence, the tool 10 is moved (again, using the robotic control workstation 300) back into position to resume normal operation.

[0088] When tool 10 is operated, magazine 30 automatically loads a single fastener strip into the side opening of the fastener driving tool. Magazine 30 has the capability to load individual fastener strips one at a time from cartridges of fasteners preloaded in the magazine by high-volume loader 200. Magazine 30 also has a biased guide that urges the fastener strip in an upward direction as it is loaded into tool 10. Therefore, using this biased guide, staples of various lengths can be loaded into the tool because the staples are oriented downward (in the driving direction of the tool) and therefore different sizes (lengths) of staples can be loaded into and driven by tool 10 without having to modify any components within the tool.

[0089] In the embodiment shown, each cartridge 32 includes a plurality of staple strips positioned next to one another. In the shown orientation of the staple strips, each staple is oriented downward, or in other words, the staple opening is at the bottom, the staple width is horizontal, and the staple length is vertical. It will be understood that fasteners other than staples, such as strips of nails, strips of headless nails, or strips of pins, can be used with this system.

[0090] In the illustrated embodiment, the staples are typically oriented so that each staple includes a width arm (i.e., an arm having a horizontal width dimension) and two legs of equal length attached to the end of the arm. The legs extend vertically downward, forming a bottom opening between the legs. A staple constructed and oriented in this manner will have two legs that are driven into a target substrate by a fastener driving tool driver.

[0091] As partially discussed above, each cartridge 32 of staples is loaded into loading station 200, and the intact cartridge is then loaded into magazine 30 of fastener driving tool 10. Once in magazine 30, each individual staple strip is loaded into a guide body at a side entrance so that each individual staple of that strip can be driven into a target workpiece. Once the last staple of an individual staple strip has been driven, magazine 30 has the ability to automatically push the next staple strip into an operative position so that the individual staples of that strip can be driven by tool 10.

[0092] 14 and 15, an exemplary assembly line 320 is shown. The exemplary assembly line 320 includes a robotic control workstation 300 exhibiting an upper arm 302, a tool 10 mounted on the workstation 300, a loading station 200, an assembly line 312, a workpiece 314, and a human user 310. It should be noted that the assembly line 312 comprises an essentially flat roller bed such that parts being assembled using the fastener driving tool 10 can be easily moved along the assembly line.

[0093] 17, a flowchart illustrating some of the major functions of the "Fastener Loading Sequence" begins at reference numeral 500. Next, in function 510, the robotic control workstation begins normal operation, i.e., the tool 10 is in use driving fasteners into a workpiece. Then, in action decision 512, the tool 10 checks whether the magazine 30 is empty. If no, normal operation continues. However, if yes, in function 514, the tool 10 will be moved (using the robotic control workstation 300) proximate the automatic fastener loading station 200.

[0094] At function 516, the magazine door 34 is automatically opened. Then, at function 518, the tool 10 is moved (using the robotic control workstation 300) into contact with the loading station 200. At action decision 520, the loading station 200 checks whether the magazine 212 contains at least one fastener cartridge 32. If no, at function 522, a human user must now manually reload the magazine 212 at the loading station 200.

[0095] However, if at least one fastener cartridge is present in decision 520 (i.e., the result is YES), then in function 524 the loading station 200 automatically moves down the next nested fastener cartridge 32. Then, in function 526, the loading station 200 pushes out the single fastener cartridge 32, placing it on a guide at the exit end of the loader 220. This pushing action simultaneously inserts the cartridge 32 into the magazine 30.

[0096] In function 528, the tool 10 is moved (using the robotic control workstation 300) out of contact with the loading station 200. The magazine door 34 then automatically closes in function 530. Next, in function 532, the tool 10 is moved (using the workstation 300) distal to the loading station 200, and in function 540, the tool 10 is repositioned to its operating position where it returns to normal operation.

[0097] First Alternative Embodiment

[0098] 16, a first alternative embodiment automated fastener driving tool is generally designated by the reference numeral 400. Tool 400 includes a housing 412, a fastener exit end 414, an extension magazine 410, and a support brace 416 for extension magazine 410. In this embodiment, extension magazine 410 includes a much longer guide capable of holding multiple fastener cartridges 32, thus reducing the number of trips to the loading station during normal operation.

[0099] Second Alternative Embodiment

[0100] Referring now to FIG. 18 , a loading station of a second alternative embodiment is generally designated by the reference numeral 600. The loading station 600 has an outer housing 614, a loading door 604 (sometimes referred to herein as the “entrance loading portion”) on one side (see FIG. 19 ), and a motor housing 608 having a motor 606 therein that drives the loading station. The loading station 600 includes an opening at an exit end 602 (sometimes referred to herein as the “dispensing exit portion”) opposite the loading door 604. The opening at the exit end 602 is used to dispense a single fastener “cartridge” 32 at a time into an automated fastener driving tool, while the loading door 604 is used to fill the loading station 600 with multiple fastener cartridges 32. Each cartridge holds several hundred fasteners 32, and the loading station 600 is capable of holding several cartridges (i.e., the loading station can hold thousands of fasteners).

[0101] Proximal to the opening at the outlet end 602 is a guide subassembly ("S / A") 620 that guides and holds the cartridge 32 during the loading operation. Guide S / A 620 includes a pusher 616, a first guide 622, a second guide 624, a vertical pusher portion 626, a horizontal pusher portion 628, and a loading arm 630. When the loading station 600 is between loading cycles, the pusher 616 is retracted inside the loading station.

[0102] During a loading event, fastener cartridge 32 is then loaded onto pusher 616 by moving from a position above loading arm 620 down loading arm 630 and "dropping" cartridge 32 onto horizontal portion 628. Pusher 616 is moved along loading arm 630, and vertical portion 626 pushes cartridge 32 through an opening in exit end 602. First guide 622 and second guide 624 both guide cartridge 32 as pusher 616 is moved.

[0103] Referring now to FIG. 19, some of the internal features of the loading station 600 are shown. A first chain drive 650 includes a first lower sprocket 654 and a first upper sprocket 652, and a second chain drive 670 includes a second lower sprocket 674 and a second upper sprocket 672 (see FIG. 20). The first lower sprocket 654 is mechanically keyed to the second lower sprocket 674, and the first upper sprocket 652 is mechanically keyed to the second upper sprocket 672. The first chain drive 650 has a first continuous chain 656, and the second chain drive 670 has a second continuous chain 676 (see FIG. 20). Both the first chain 656 and the second chain 670 rotate in a counterclockwise direction, indicated as direction line D.

[0104] Both the first chain drive 650 and the second chain drive 670 move from the inlet loading section 604 to the distribution outlet section 602 and then back to the inlet loading section 604 by rotation within the outer housing 614 .

[0105] First elongated rail 662, second elongated rail 664, third elongated rail 666, and fourth elongated rail 668 direct and guide first drive chain 650 as it rotates around first upper sprocket 652 and first lower sprocket 654. Similarly, fifth elongated rail 682, sixth elongated rail 684, seventh elongated rail 686, and eighth elongated rail 688 direct and guide second drive chain 670 (see FIG. 20 ).

[0106] A plurality of carrier gears 644 are attached to both the first drive chain 656 and the second drive chain 676. A first plurality of movable carriers 658 (sometimes referred to herein as a first plurality of elevators or movable shelves) are attached to the plurality of carrier gears 644 mounted on the first drive chain 656. A second plurality of movable carriers 660 (sometimes referred to herein as a second plurality of elevators or movable shelves) are attached to the plurality of carrier gears 644 mounted on the second drive chain 676. The first plurality of carriers 658 and the second plurality of carriers 660 are formed as pairs of angle brackets, each mounted flat (parallel to vertical) to hold cartridges 32 (see, for example, FIG. 22 ). The first plurality of movable carriers 658 are positioned opposite the second plurality of movable carriers 660 so that they do not contact each other and have an open space between them.

[0107] As the first and second chain drives 650 and 670 rotate, each set of paired (parallel) carriers 658 and 660 and the plurality of carrier gears 644 move along the paths of the two chain drives. The plurality of paired carriers 658 and 660 remain substantially horizontal relative to each other and to the guide S / A 620. When a fastener cartridge 32 is loaded into the loading station 600 by a user, a fastener is placed on each of the paired sets of carriers 658 and 660, such that the legs of the staple rest on each carrier half (i.e., on each of the paired angle brackets).

[0108] During a loading event, one pair of the plurality of paired carriers 658 and 660 moves from above the guide S / A 620 to below the guide S / A. Due to the "gap" or "opening" between the paired carriers 658 and 660, the horizontal portion of the staples 32 hooks the horizontal pusher 628, and the cartridge 32 is held on the horizontal pusher until it is loaded into the automated fastener driving tool. This process is repeated until the loading station 600 has deployed all of its staple cartridges 32. The user then manually loads each of the paired carriers through the loading door 604.

[0109] A first rail 632 is attached to the exterior of the housing 614. The first rail 632 defines a first elongated slot 636 and a second elongated slot 637. A first plurality of fasteners 640 are attached within the first and second elongated slots 636 and 637. A second rail 634 is attached to the exterior of the housing 614 opposite the first rail 632 (see FIG. 25). The second rail 634 defines a third elongated slot 638 and a fourth elongated slot 639 (shown in FIG. 25). A second plurality of fasteners 642 are attached within the third and fourth elongated slots 638 and 639, as shown in FIG. 25.

[0110] Referring now to FIG. 20 , a further view of the interior of loading station 600 is shown, along with base portion 618. FIG. 20 more clearly shows each of paired carrier sets 658 and 660, with multiple carriers 658 and 660 attached along the entire length of both first and second drive chains 656 and 676. When motor 606 is started, it rotates lower gear shaft 649, which rotates both first lower sprocket 654 and second lower sprocket 674. Both lower sprockets 654 and 674 then begin to rotate first drive chain 656 and second drive chain 676 in a counterclockwise direction. As long as motor 606 is running, the two chains 656 and 676 rotate first upper sprocket 652 and second upper sprocket 672 in sync with the lower sprockets 654 and 674. Because all of the sprockets 654, 674, 652, 672 and both chains 656, 676 rotate synchronously with one another, the multiple carriers 658, 660 also rotate synchronously. This synchronous rotation allows the multiple carriers 658 and 660 to remain substantially parallel (horizontal) with one another, allowing the carriers 658 and 660 to hold a single cartridge of fasteners 32 in each "pair" of carriers without dropping the cartridge.

[0111] 21 , an enlarged view of a portion of the interior of the loading station 600 is shown. The plurality of carriers 658 and 660 exhibit a front wall 692, a rear wall 694, and a floor portion 696. The first plurality of carriers 658 includes a first elongated wall 690 proximal to the first chain drive 656, and the second plurality of carriers 660 includes a second elongated wall 698 proximal to the second chain drive 676. The elongated walls 690 and 698 face each other with the floor portion 696 between them. This configuration allows cartridges 32 to be positioned on the plurality of carriers 658 and 660 without slipping off. The front wall 692 and rear wall 694 also ensure that the cartridges 32 are securely seated on the plurality of carriers 658 and 660.

[0112] 22, several cartridges 32 of fasteners are shown loaded within loading station 600. One cartridge 32 is loaded onto horizontal pusher 628 and is ready to be inserted into the fastener driving tool magazine. Two other cartridges 32 are waiting to be loaded sequentially onto pusher 616. In FIG. 22, loading station 600 has nearly dispensed all of its cartridges 32, which means that the user will need to reload multiple carriers 658 and 660 once all of the cartridges have been dispensed.

[0113] 23 shows a cartridge 32 that has just been loaded onto the pusher 616. As described above, the two chain drives 650 and 670 rotate counterclockwise, causing one of the carriers 658 and 660 to move directly above the pusher 616. Because there is a gap between both floors 696 of each carrier 658 and 660, the cartridge 32 "drops" onto the horizontal pusher 628 while the carrier continues to move counterclockwise, out of the path of the pusher 616.

[0114] 24 shows the pusher 616 actuated, moving the cartridge 32 through the opening in the exit end 602 and all the way to the "left" (in this view) on the loading arm 630. Once this cartridge 32 has finished loading into the tool magazine, the pusher 616 retracts inside the loading station 600 to await the next cartridge 32.

[0115] 25, there is shown a rear view of loading station 600. Load door 604 has an opening 680 which can be left open for easy access to the interior of loading station 600, or which can be filled with, for example, glass or acrylic. It is preferable to fill opening 680 to help keep dust and other workplace contaminants out of loading station 600 as much as possible.

[0116] Referring now to FIG. 30, most of the autoloader 600 is hidden in this view to better illustrate the second chain drive 670. The second chain drive 670 includes a second upper sprocket 672 and a second lower sprocket 674 (as described above). The first upper leveling gear 646 is in mechanical communication with the second upper sprocket 672, and the first lower leveling gear 648 is in mechanical communication with the second lower sprocket 674. It should be noted that the first upper sprocket 652 and the first lower sprocket 654 are in mechanical communication with the second upper leveling gear 633 and the second lower leveling gear 635, respectively (see FIGS. 41 and 42).

[0117] During operation, the motor 606 rotates a lower gear shaft 649 (sometimes referred to herein as the “second gear shaft”). All of the lower gears are in mechanical communication with this lower gear shaft 649. An upper gear shaft 643 (sometimes referred to herein as the “first gear shaft”) is in mechanical communication with all of the upper gears. When the second chain drive 670 and the first chain drive 650 are in motion, the lower gear shaft 649 drives the rotation, and the upper gear shaft 643 rotates simultaneously due to the mechanical linkage between the first drive chain 656 and the second drive chain 676. The plurality of carrier gears 644 contact the first upper leveling gear 646 and the first lower leveling gear 648 during rotation of the first and second chain drives 650 and 670. (Similarly, the plurality of carrier gears 644 contact the second upper leveling gear 633 and the second lower leveling gear 635 in the same manner.)

[0118] 31, the motor 606 is shown proximate the base 618 of the autoloader 600. In this view, the motor housing 608 is not shown. As mentioned above, the motor 606 drives the lower gear shaft 649 when the chain drives 650 and 670 are operating.

[0119] Referring now to FIG. 32, several of the multiple carrier gears 644 are shown rotating around the first lower leveling gear 648. During this rotation, each carrier 658 remains substantially parallel to the base 618 of the autoloader 600. The translational movement of the carriers is made possible due to a sun gear and planet gear set mounted inside the first lower leveling gear 648 (see FIG. 36). It should be noted that separate sun gear and planet gear sets are also mounted inside the first upper leveling gear 646, the second upper leveling gear 633, and the second lower leveling gear 635 (see FIGS. 40-42).

[0120] Referring now to Figure 33, there is shown a cutaway view taken along section line 33-33 of Figure 32. As can be seen in Figure 33, the lower gear shaft 649 passes through both the first lower leveling gear 648, the second lower sprocket 674, and the motor 606.

[0121] 34, there is shown the spacing between the second drive chain 676 and the plurality of carrier gears 644. The plurality of carrier gears 644 never contact the second drive chain 676, but rather contact and mesh with the first lower leveling gear 648 as each carrier 658 rotates about the lower gear shaft 649.

[0122] 35, there is shown the second drive chain 676 and the second lower sprocket 674. Fifth, sixth, seventh, and eighth elongated guides 682, 684, 686, 688 keep the second drive chain 676 oriented to keep the carrier 658 substantially parallel to the base 618 of the autoloader 600 during operation.

[0123] 36 , there is shown a first sun gear 641 and a first plurality of planetary gears 645 mounted within a first lower ring gear 619. The first lower ring gear 619 is part of the inner circumference of a first lower leveling gear 648. In operation, as each carrier gear 644 (and its associated carrier 658) moves into contact with the first lower leveling gear 648, the first sun gear 641 and the plurality of planetary gears 645 rotate with the first lower ring gear 619, ensuring that the orientation of the carrier 658 remains substantially parallel to the base 618 of the autoloader 600 until the carrier gear 644 moves out of contact with the first lower leveling gear 648.

[0124] During operation, the multiple carrier gears 644 do not rotate until they contact one of the first upper leveling gear 646, the first lower leveling gear 648, the second upper leveling gear 633, or the second lower leveling gear 635, and then rotate only enough to keep each carrier 658 substantially parallel to the base 618 of the loader 600 until contact ends. After this contact ends, the elongated rails 636, 637, 638, 639, 662, 664, 666, 668 ensure that the carrier 658 remains substantially parallel to the base 618 of the loader 600 until each carrier gear 644 again contacts one of the other leveling gears 646, 648, 633, or 635.

[0125] 36, the plurality of planetary gears 645 is shown as six separate planetary gears. It is contemplated that a designer may increase or decrease the number of planetary gears while simultaneously increasing or decreasing the size of the first sun gear 641 and / or the first lower leveling gear 648. The exact design and number of planetary gears will depend on the size of the lifter and how far the carrier 658 must move around the first lower leveling gear 648 in order for the sun gear and planetary gears to maintain an orientation such that each carrier remains substantially parallel to the base 618 of the loader 600.

[0126] Referring now to FIG. 40 , there is shown a second sun gear 612 and a second plurality of planetary gears 613 attached to a second lower ring gear 627. The second lower ring gear 627 is part of the inner circumference of a second lower leveling gear 635. The second sun gear 612, the second plurality of planetary gears 613, the second lower ring gear 627, and the second lower leveling gear 635 operate in a manner similar to the first sun gear 641, the first plurality of planetary gears 645, and the first lower leveling gear 648 shown in FIG. 36 and described above. The gears 612, 613, 635, and sprocket 654 shown in FIG. 40 are in mechanical communication with the gears 641, 645, 648, and sprocket 674 shown in FIG. 36 due to their mechanical connection to a second gear shaft 649. It should be noted that the first lower sprocket 654 is in direct mechanical communication with the second gear shaft 649, so that the motor 606 directly drives the gears 612, 613, 635 and sprocket 654 shown in FIG.

[0127] Referring now to FIG. 41 , there is shown a third sun gear 615 and a third plurality of planetary gears 617 mounted within a first upper ring gear 625. The first upper ring gear 625 is part of the inner circumference of a first upper leveling gear 646. The first gear shaft 643 is not directly driven by the motor 606, but rather rotates when the motor 606 drives the second gear shaft 649, thereby rotating the second lower sprocket 674 and the first lower sprocket 654. The rotation of the two lower sprockets 654 and 674 drives both chain drives 650 and 670, thereby rotating the first upper sprocket 652 and the second upper sprocket 672. The gears 615, 617, 625, 646 and sprocket 672 shown in FIG. 41 operate similarly to the gears shown in FIGS. 36 and 40 , except that the motor 606 indirectly drives their rotation.

[0128] Referring now to FIG. 42 , there is shown a fourth sun gear 621 and a fourth plurality of planetary gears 623 attached to a second upper ring gear 629. The second upper ring gear 629 is part of the inner circumference of a second upper leveling gear 633. As noted above, the gears 621, 623, 629, 633 and sprocket 652 shown in FIG. 42 operate similarly to the other gears shown in FIGS. 36 , 40 , and 41 . The gears 621, 623, 629, 633 and sprocket 652 shown in FIG. 42 are in mechanical communication with the gears 615, 617, 646 and sprocket 672 shown in FIG. 41 due to the fact that both the first upper sprocket 652 and the second upper sprocket 672 are directly mechanically coupled to the first gear shaft 643.

[0129] 43 , there is shown a preferred method of attaching one of the first movable carriers 658 and one of the carrier gears 644 to the second drive chain 676. The carrier gear 644 exhibits a blind hole 679 that fits onto a carrier shaft 683, which is attached at a connection end 681 to the second chain drive 676. A pair of carrier fasteners 678 are used to securely attach the first movable carrier 658 to the carrier gear 644. When the loading station 600 is in operation, when the carrier gear 644 contacts one of the leveling gears 633, 635, 646, and 648, the carrier gear 644 is able to rotate about the carrier shaft 683, thereby maintaining the movable carrier 658 substantially parallel to the base 618.

[0130] Third Alternative Embodiment

[0131] 26, a third alternative embodiment automated fastener driving tool is generally designated by the reference numeral 710. Tool 710 includes at least one external pressurized gas connector 720, at least one connector 722 for an external controller, a fastener exit end 726, a guide body 728, and an outer housing 724.

[0132] The tool 710 also includes an automatically operating magazine 730, which allows the loading station 600 to automatically load a cartridge of fasteners 32. An external controller 810 (see FIG. 39) can send commands to the tool 710 during operation. For example, the tool 710 can drive fasteners until the magazine 730 is empty, and then open the magazine 730 to accept a cartridge 32 from the loading station 600.

[0133] The magazine 730 includes several features to assist in the automatic loading sequence. A first piston 742 is actuated to open and close a pivotable door 734 on the magazine 730. The first piston 742 can receive actuation commands from an external controller 810 or an on-board CPU 840 (see FIG. 39 ). The magazine 730 also includes a cover 736, a receiving portion 738 (for the fastener cartridge 32), and a clamp subassembly (“S / A”) 740.

[0134] Clamp S / A 740 is attached to door 734 and includes a holder 744 that prevents fastener cartridge 32 from falling out of magazine 730, and a pair of removably attachable plates 750. These plates 750 can assume varying heights depending on the type of fasteners loaded in magazine 730. If short fasteners are loaded, plates 750 with a low height profile (measured from door 734 to the top of plates 750) can be installed. Alternatively, if taller fasteners are loaded, plates 750 can be replaced with ones with a higher height profile.

[0135] Other features of the magazine 730 include a front plate 752, a back plate 746 that maintains tension on the fastener cartridge 32 (i.e., pushing the cartridge toward the front plate), a magazine pusher 748 (see FIGS. 27-29), a stop plate 754 at the deepest portion of the magazine, and a pair of support plates 756 that help support the fastener cartridge 32 during a loading event. The back plate 746 is biased by a second piston 747 that biases the back plate 746 toward the stop plate 754, so that when the previous cartridge is used, the onboard CPU 840 can "reset" the back plate 746 (i.e., move the back plate 746 in the direction away from the stop plate 754) to accept a new cartridge of fasteners 32. As described above, during a loading event, the door 734 and plate 750 open and drop away from the magazine 730. When loading station 600 pushes fastener cartridge 32 into receiving portion 738, the staple legs slide and then rest on support plate 756 until door 734 is closed, at which point plate 750 and support plate 756 hold fastener cartridge 32 within the magazine.

[0136] The structure of the magazine 730 completely encloses the fastener 32 when the tool 710 is in use. Due to this structure, the tool 710 can be utilized at any position within the three-dimensional work environment.

[0137] 27, cover 736 is not shown in this view to better show magazine pusher 748. FIG. 27 also provides a close-up view of the height of plate 750.

[0138] 28 and 29 show a magazine pusher 748 used with a fastener cartridge 32. In FIG. 28, a new cartridge 32 has been loaded into the magazine 730. The magazine pusher 748 is in a distal-most position from the guide body 728, and the magazine pusher 748 provides a force to push the cartridge 32 toward the guide body 728. As the tool 710 begins to drive fasteners 32, the magazine pusher 748 continuously pushes the cartridge 32 toward the guide body 728 to sequentially load the fasteners into the guide body and then into the substrate.

[0139] 29, the magazine pusher 748 is moving from right to left (in this view) and somewhat closer to the guide body 728. The cartridge 32 is continually urged toward the left (in this view) by the magazine pusher 748 to successively load fasteners into the guide body 728. The "right to left" movement of the magazine pusher 748 continues until the tool stops operating or the cartridge 32 is completely used.

[0140] Fourth Alternative Embodiment

[0141] 37, a fourth alternative embodiment loading station is generally designated by the reference numeral 900. Loader 900 includes a plurality of gears 944 and associated carriers 958, and a guide subassembly ("S / A") 920 including a pusher 916, a vertical portion 926, a horizontal portion 928, and a loading arm 930. In FIG. 37, loading arm 930 is shown in a retracted position.

[0142] Referring now to FIG. 38 , the loading arm 930 is shown in an extended position. The telescoping arm 931 is shown fully extended, allowing the loading arm 930 to reach far enough into the magazine of the automated fastener driving tool to successfully load a cartridge of fasteners. The telescoping arm 931 is comprised of at least two ultra-thin, independent sliding sections used for a double telescoping motion. This telescoping motion allows the loading arm 930 to extend far enough to load a cartridge of fasteners into the magazine (as shown in the previous embodiment). In FIG. 38 , the telescoping arm 931 is shown with three telescoping sections, designated as a first telescoping section 932, a second telescoping section 934, and a third telescoping section 936.

[0143] Electronic Block Diagram

[0144] 39, there is shown in block diagram form the electronic circuitry of the fastener driving tool 710, loading station 600, and external controller 810. In the illustrated embodiment, the fastener driving tool 710 includes a microprocessor (CPU) 840, flash memory 842, random access memory (RAM) 844, an EEPROM (electrically erasable programmable read-only memory) 846, and a power source (such as a battery) 856.

[0145] An input / output (I / O) interface circuit 848 is included to provide signal conditioning as needed between CPU 840 and other components that typically use voltage and / or current levels that cannot typically be directly connected to a processing device, such as sensors. Each appropriate I / O signal is routed through a separate channel of I / O interface circuit 848, unless two or more signals of a particular voltage and current rating may be multiplexed, in which case multiplexer circuitry may be included within I / O interface circuit 848. Data signals between I / O circuit 848 and CPU 840 flow through a low-voltage signal bus 856.

[0146] In this embodiment, a data interface in the form of a LAN / WAN radio 854 is included to enable CPU 840 to communicate with other external devices, such as external controller 810. External controller 810 also includes a LAN / WAN radio 820, which communicates with radio 854 using a proprietary protocol, if necessary. However, radios 854 and 820 may use any number of different communication protocols, such as Bluetooth, although data structures in messages between radios 854 and 820 may certainly be encrypted or otherwise formatted in a proprietary manner. Radios 854 and 820 may also include other types of wireless communication devices that may not operate strictly on radio principles, including types of wireless communication devices not yet invented.

[0147] The microprocessor 840 controls the operation of the tool 710 according to programmed instructions received from the external controller 810 and stored in memory circuits such as flash memory 842. RAM memory 844 is typically used to store various data elements such as counters, software variables, and other informational data. EEPROM memory 846 is typically used to store more permanent tool data such as operating cycles, configuration information, and other important data. It will be understood that many different types of microprocessors or microcontrollers can be used in the tool 710 and many different types of memory circuits can be used to store data in both volatile and non-volatile form without departing from the principles disclosed herein.

[0148] A power supply 856 provides operating power for the tool 710. It will be appreciated that the power supply 856 can be a battery or an external power source. A magazine sensor 850 can be used to notify the CPU 840 (or alternatively, the external controller 810) when the magazine 730 is empty or full. A “fired” feedback signal sensor 852 can be used to notify the CPU 840 or the external controller 810 when a fastener has been driven. This “fired” feedback signal sensor 852 is preferably a linear high-resolution sensor that can perform fault processing and fire proofing by combining fastener movement on a millisecond basis with the presence of a “fired” feedback signal. The external controller 810 includes a microprocessor (CPU) 812, a RAM (random access memory) 814, an EEPROM (electrically erasable programmable read-only memory) 816, and a power source (such as a battery) 822.

[0149] An input / output (I / O) interface circuit 818 is included to provide signal conditioning as needed between the CPU 812 and other components that typically use voltage and / or current levels that cannot typically be directly connected to the processing device, such as sensors. Each appropriate I / O signal is routed through a separate channel in the I / O interface circuit 818, unless two or more signals of a particular voltage and current rating may be multiplexed, in which case multiplexer circuitry may be included within the I / O interface circuit 818. Data signals between the I / O circuit 818 and the CPU 812 flow through a low-voltage signal bus.

[0150] Microprocessor 812 controls the operation of external controller 810 according to programmed instructions stored in memory circuits. It will be understood that many different types of microprocessors or microcontrollers can be used in external controller 810 and many different types of memory circuits can be used to store data in both volatile and non-volatile form without departing from the principles disclosed herein.

[0151] A power supply 822 provides operating power for the external controller 810. It will be appreciated that the power supply 822 can be a battery or an external power source. In a production line environment, AC line voltage will generally be available, and the power supply 822 will typically be a DC power supply that provides direct current at voltage levels appropriate to the controller and any sensors and input / output interface circuitry used in the system.

[0152] Load station 600 includes a microprocessor (CPU) 870, random access memory (RAM) 872, an EEPROM (electrically erasable programmable read-only memory) 874, and a power source (such as a battery) 886. An input / output (I / O) interface circuit 876 is included to provide signal conditioning as needed between CPU 870 and other components that typically use voltage and / or current levels that cannot be directly connected to a processing device, such as sensors. Each appropriate I / O signal is routed through a separate channel in I / O interface circuit 876, unless two or more signals of a particular voltage and current rating may be multiplexed, in which case a multiplexer circuit may be included within I / O interface circuit 848. Data signals between I / O circuit 876 and CPU 870 flow through a low-voltage signal bus.

[0153] In this embodiment, an optional data interface in the form of a LAN / WAN radio 882 is included to enable CPU 870 to communicate with other external devices. Radio 882 may use any number of different communication protocols, such as Bluetooth, although the data structures in the messages may certainly be encrypted or otherwise formatted in a proprietary manner. Radio 882 may also include other types of wireless communication devices that may not operate strictly on radio principles, including types of wireless communication devices not yet invented.

[0154] Microprocessor 870 controls the operation of loading station 600 according to programmed instructions stored in memory circuits. It will be understood that many different types of microprocessors or microcontrollers may be used in loading station 600 and many different types of memory circuits may be used to store data in both volatile and non-volatile form without departing from the principles disclosed herein.

[0155] A power supply 886 provides operating power for the loading station 600, including the chain drive motor circuit 884. The motor circuit 884 drives the motor 606. It will be appreciated that the power supply 856 may be a battery or an external power source. A load arm sensor 878 may be used to notify the CPU 870 when the load arm is empty, full, extended, or retracted. A carrier sensor 880 may be used to notify the CPU 870 when one of a plurality of carriers is being loaded or unloaded.

[0156] It should be noted that, for purposes of clarity, some of the embodiments shown herein do not have all of their components included in some of the drawings herein. To see examples of such outer housings and other components, particularly with respect to earlier designs, the reader is referred to other U.S. patents and applications owned by Kyocera Senco. Similarly, information regarding "how" the electronic controller operates to control tool functions can be found in other U.S. patents and applications owned by Kyocera Senco. Furthermore, other aspects of the tool technology of the present invention may be present in conventional fastener driving tools sold by assignee Kyocera Senco Industrial Tools, Inc., including information disclosed in earlier U.S. patents and published applications. Examples of such publications are U.S. Patent Nos. 6,431,425, 5,927,585, 5,918,788, 5,732,870, 4,986,164, 4,679,719, 8,011,547, 8,267,296, 8,267,297, 8,011,441, 8,387,718, 8,286,722, 8,230,941, 8,602,282, 9,602,296, and 9,602,297. Nos. 76,088, 10,478,954, 9,993,913, 10,549,412, 10,898,994, 10,821,585, and 8,763,874, as well as U.S. Patent Application Publication Nos. 2020 / 0156228, 2021 / 0016424, 2020 / 0070330, 2020 / 0122308, and U.S. Provisional Patent Application No. 63 / 331993, filed April 18, 2022, all of which are incorporated herein by reference in their entireties.

[0157] It will also be understood that the exact logical operations shown in the flowchart of FIG. 17 and described above can be modified somewhat, perhaps to function similarly, though less exactly, without departing from the principles of the technology disclosed herein.

[0158] As used herein, the term "proximal" may refer to the placement of one physical object in close proximity to a second physical object, such that the two objects are potentially adjacent to one another, but does not necessarily require the absence of a third object disposed between them. In the technology disclosed herein, a "male positioning structure" may be positioned "proximal" to a "female positioning structure." Generally, this may mean that the two (male and female) structures physically abut one another, or that they are "mated" to one another by virtue of a particular size and shape that essentially holds one structure oriented relative to the other and in an XY (e.g., horizontal and vertical) position, regardless of whether the two (male and female) structures actually contact one another along a continuous surface. Alternatively, two structures of any size and shape (whether male, female, or other) may be positioned somewhat near one another, regardless of whether they physically abut one another, and such a relationship can still be referred to as "proximal." Alternatively, two or more possible locations for a particular point can be specified relative to a precise attribute of a physical object, such as being "near" the end of a rod or being "at" the end of a rod, and all of those possible near / at locations can be considered "proximal" to that end of the rod. Furthermore, the term "proximal" can also have a meaning strictly related to a single object, where a single object may have two ends, the "distal end" being the end located somewhat farther away from a target reference point (or region), and the "proximal end" being the other end that would be located somewhat closer to that same target reference point (or region).

[0159] It will be understood that the various components described and / or shown herein can be manufactured in a variety of ways, including being fabricated in multiple parts or as a unitary piece for each of these components, without departing from the principles of the technology disclosed herein. For example, a component included as a recited element in the following claims may be fabricated as a unitary piece, or the component may be fabricated as a combined structure of several individual parts assembled together. However, that "multiple-piece component" would still be included within the scope of the claimed recited element for infringement purposes of claim interpretation, even if the claimed recited element appears to be described and shown herein only as a unitary structure.

[0160] All documents cited in the "Background" and "Detailed Description" sections are, in relevant part, incorporated herein by reference; the citation of any document should not be construed as an admission that it is prior art to the technology disclosed herein.

[0161] The foregoing description of the preferred embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the technology disclosed herein to the precise form disclosed, as the technology disclosed herein can be further modified within the spirit and scope of the disclosure. Any examples described or shown herein are intended as non-limiting examples, and many modifications or variations of those examples or preferred embodiments are possible in light of the above teachings without departing from the spirit and scope of the technology disclosed herein. The embodiments have been chosen and described in order to illustrate the principles of the technology disclosed herein and its practical application, thereby enabling those skilled in the art to utilize the technology disclosed herein in various embodiments and with various modifications suitable for the particular use contemplated. This application is therefore intended to cover any variations, uses, or adaptations of the technology disclosed herein using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this technology is pertaining and which fall within the scope of the appended claims.

Claims

1. An automatic fastener loading machine (200, 600, 900) comprising: An outer housing (24, 614) including an inlet loading section (210, 604), a main holding section, and a dispensing outlet section (216, 602), the inlet loading portion includes a first opening sized and shaped to receive at least one cartridge, the at least one cartridge including a plurality of fasteners (32); the main retention portion is sized and shaped to accommodate a plurality of the at least one cartridge; the dispensing outlet portion comprises an outer housing having a second opening sized and shaped to dispense the at least one cartridge; (a) the outer housing at least partially encloses a plurality of movable shelves (658, 660), each sized and shaped to hold the at least one cartridge; (b) the plurality of movable shelves are connected to a drive system (650, 670) that moves the movable shelves from the entrance loading portion to the dispensing exit portion while having the ability to transport the at least one cartridge; (c) an automated fastener loader, wherein when one of the plurality of movable shelves reaches the dispensing outlet portion, the drive system allows the at least one cartridge to be moved through the second opening, thereby allowing it to be unloaded from the automated fastener loader.

2. 2. The automated fastener loading machine of claim 1, wherein the drive system comprises at least one continuous chain connected to the plurality of movable shelves for moving each movable shelf by rotation within the loader from the entrance loading section to the dispensing exit section and then back to the entrance loading section.

3. 3. The automated fastener loader of claim 2, wherein the drive system uses a plurality of sprockets that function as prime movers for the at least one continuous chain.

4. (a) the dispensing outlet portion (216, 602) includes a mechanical guide (220, 630, 930) that assists in accurately positioning the at least one cartridge within a receiving opening (38, 738) of a magazine (30, 730) for a fastener driving tool (10, 710); or (b) the at least one cartridge comprises a plurality of fastener strips arranged adjacent to one another, the fasteners (32) facing downward; or (c) the fastener (32) Staples, pin, tacks, or headless nails, or (d) the fasteners (32) are staples (32), each staple (32) having a wide arm and two legs of equal length attached to the end of the arm, forming a bottom opening between the legs; 10. The automated fastener loading machine (200, 600, 900) of claim 1.

5. A magazine (30, 730) for use with a fastener driving tool (10, 710), said magazine comprising: a cover portion (36, 736) including a pivotable door (34, 734); a receiving portion (38, 738) for receiving a cartridge through said pivotable door in an open position; an outlet portion including an outlet opening proximal to the guide body (28, 728) of the fastener driving tool (10, 710); a clamp (40, 740) attached to the pivotable door, the clamp urging the cartridge toward one side of the magazine proximate the exit opening; The cartridge comprises a plurality of fastener strips (32) arranged next to each other, the fasteners facing downward; the cartridge presents a lead strip of fasteners arranged to be subsequently loaded into the guide body; the lead strip of the fastener is biased upward toward the exit opening regardless of the length of the fastener within the lead strip; The pivotable door is controlled by an actuator (742) and remains closed except when a cartridge is loaded in the receiving portion.

6. (a) the magazine is operable to hold various types of cartridges of fastener strips (32) of different lengths; or (b) the fastener (32) Staples, pin, tacks, or headless nails, or (c) the fasteners (32) are staples (32), each staple (32) having a wide arm and two legs of equal length attached to the end of the arm, forming a bottom opening between the legs; or (d) When the fastener loading sequence is initiated: the pivotable door (34, 734) is automatically opened; At least one cartridge is inserted into the second side; the pivotable door is automatically closed; A magazine (30, 730) according to claim 5.

7. A magazine (30, 730) for use with a fastener driving tool (10, 710), said magazine comprising: a cover portion (36, 736) including a pivotable door (34, 734); a receiving portion (38, 738) for receiving a cartridge through said pivotable door in an open position; an outlet portion including an outlet opening proximal to the guide body (28, 728) of the fastener driving tool (10, 710); a clamp (40, 740) mounted on the pivotable door, the clamp including a plurality of removably attachable plates (750) supporting the cartridge; The cartridge comprises a plurality of fastener strips (32) arranged next to each other, the fasteners facing downward; the cartridge presents a lead strip of fasteners arranged to be subsequently loaded into the guide body; The lead strip of fasteners is biased upward toward the exit opening regardless of the length of the fastener within the lead strip.

8. (a) each of said fastener strips (32) comprises a plurality of staples, each staple having a wide arm and two legs of equal length attached to the end of said arm and forming a bottom opening between said legs; or (b) said plurality of removably attachable plates (750) comprising: A low height plate for use with shorter leg staples, or a high height plate for use with longer leg staples; or (c) the pivotable door (34, 734) is closed during operation of a fastener driving tool (10, 710) associated with the magazine to enclose and protect the cartridge, thereby allowing the fastener driving tool to be utilized at any position within a three-dimensional work environment; or (d) the pivotable door (34, 734) is opened during a reloading operation and positioned so that the reloading station (200, 600, 900) has a clear path for loading the magazine; The magazine (30, 730) of claim 7.

9. An automatic fastener loading machine (200, 600, 900) comprising: An outer housing (24, 614) including an inlet loading section (210, 604), a main holding section, and a dispensing outlet section (216, 602), the inlet loading portion includes a first opening sized and shaped to receive at least one cartridge, the at least one cartridge including a plurality of fasteners (32); the main retention portion is sized and shaped to accommodate a plurality of the at least one cartridge; an outer housing, the dispensing outlet portion including a second opening sized and shaped to dispense the at least one cartridge; a motor (606) in mechanical communication with at least one chain drive (650, 670), said at least one chain drive including a continuous chain (656, 676); a first plurality of movable carriers (658) and an opposing second plurality of movable carriers (660), the first plurality of movable carriers and the second plurality of movable carriers being positioned so as not to contact one another and to present an open space therebetween; the first plurality of movable carriers and the second plurality of movable carriers are connected in pairs to the continuous chain of the at least one chain drive, whereby each of the first plurality of movable carriers is oriented toward each of the second plurality of movable carriers, and the chain drive is operable to move the pair of movable carriers from the entrance loading portion to the dispensing exit portion while each of the pair of movable carriers carries the at least one cartridge; and a first plurality of movable carriers and an opposing second plurality of movable carriers that allow the at least one cartridge to be moved through the second opening and thereby unloaded from the automated fastener loader when one of the pair of movable carriers reaches the dispensing outlet portion; The automated fastener loader, wherein the outer housing at least partially encloses the first and second plurality of movable carriers and the at least one chain drive.

10. (a) the at least one chain drive (650, 670) a first chain drive (650) including a first plurality of gears (652, 654) and a first continuous chain (656) driven by said first plurality of gears and rotating within said outer housing to move from said inlet loading section (210, 604) to said distribution outlet section (216, 602) and then back to said inlet loading section; a second chain drive (670) including a second plurality of gears (672, 674) and a second continuous chain (676) driven by said second plurality of gears and rotating within said outer housing to move from said inlet loading section to said distribution outlet section and then back to said inlet loading section; the first plurality of movable carriers (658) are connected to the first chain drive; the second plurality of movable carriers (660) are connected to the second chain drive; the first chain drive and the second chain drive are operable to rotate together when the motor is activated; each pair of said plurality of movable carriers moves together such that said first plurality of movable carriers remains substantially parallel to said second plurality of movable carriers; A loading station (200, 600, 900) according to claim 9.

11. (a) as the at least one chain drive (650, 670) moves, each pair of movable carriers (658, 660) moves from a position above a load arm (220, 630, 930) to a position below the load arm; one of the at least one of the cartridges is loaded onto the loading arm as one of the pair of movable carriers moves to the lower position of the loading arm; or (b) said loading arm (930) a first independent slide portion (932); a second independent slide portion (934); A loading station (200, 600, 900) according to claim 10.

12. 1. A method for dispensing fasteners (32) from an automated loading station (200, 600, 900), the method comprising: (a) providing an automated loading station (200, 600, 900), said automated loading station comprising: (i) an outer housing (24, 614) including an inlet loading section (210, 604), a main holding section, and a dispensing outlet section (216, 602); the inlet loading portion includes a first opening sized and shaped to receive at least one cartridge, the at least one cartridge including a plurality of fasteners (32); the main retention portion is sized and shaped to accommodate a plurality of the at least one cartridge; an outer housing, the dispensing outlet portion including a second opening sized and shaped to dispense the at least one cartridge; (ii) a motor (606) in mechanical communication with at least one chain drive (650, 670); (iii) a first plurality of movable carriers (658) and an opposing second plurality of movable carriers (660) at least partially enclosed by said outer housing; the first plurality of movable carriers and the second plurality of movable carriers are not in contact with each other and have an open space therebetween; the first plurality of movable carriers and the second plurality of movable carriers comprising: a first plurality of movable carriers (658) and an opposing second plurality of movable carriers (660) connected in pairs to the at least one chain drive such that each of the first plurality of movable carriers faces each of the second plurality of movable carriers, and each pair is operable to carry the at least one cartridge; (b) moving the pair of movable carriers from the inlet loading section to the dispensing outlet section using the chain drive; (c) loading said at least one cartridge from one of said pair of movable carriers onto a loading arm (220, 630, 930); (d) providing an automatic magazine (30, 730) for use with a fastener driving tool (10, 710), said magazine comprising: (i) a cover portion (36, 736) including a pivotable door (34, 734); (ii) a receiving portion (38, 738) for receiving the at least one cartridge through the pivotable door in an open position; (iii) an exit portion including an exit opening proximal to the guide body (28, 728) of the fastener driving tool (10, 710); (iv) a clamp (40, 740) mounted on said pivotable door, said clamp including a plurality of removably attachable plates (750) supporting said at least one cartridge; (e) opening the pivotable door of the magazine; (f) extending the loading arm from the dispensing outlet portion of the loading station toward the magazine; (g) loading said at least one cartridge into said magazine from said automatic loading station; (h) retracting the loading arm away from the magazine to its original position; (i) closing the pivotable door of the magazine.

13. at least one external controller (810); and a communications network that enables data messages to be transmitted between the at least one external controller and the fastener driving tool (10, 710); the at least one external controller includes a first processing circuit (812), a first memory circuit (816) containing instructions executable by the first processing circuit, and a first communication circuit (820); the fastener driving tool includes a second processing circuit (840), a second memory circuit (846) containing instructions executable by the second processing circuit, and a second communications circuit (854); the at least one external controller transmits a data message to the fastener driving tool using the communications network, the data message including additional instructions executable by the second processing circuit; The method of claim 12.

14. The fastener driving tool (10, 710) includes at least one sensor, the sensor comprising: a magazine sensor (850), or At least one of the "fire" signal sensors (852); The method of claim 13.

15. The at least one chain drive (650, 670) a first chain drive (650) including a first gear system (652, 654) and a first continuous chain (656) driven by said first gear system; a second chain drive (670) including a second gear system (672, 674) and a second continuous chain (676) driven by said second gear system; 13. The method of claim 12, wherein when the motor (606) is activated, the first gear system and the second gear system rotate together, thereby synchronizing the movement of the first chain drive and the second chain drive.

16. (a) the first gear system (652, 654) a first plurality of planetary gear sets, each of the first plurality of planetary gear sets including a first sun gear (612, 621), a first plurality of planet gears (613, 623), and a first ring gear (627, 635, 629, 633); a first plurality of carrier gears (644) attached to said first continuous chain (656); the first ring gear is in mechanical communication with the first plurality of carrier gears that follow along the path of a first continuous chain (656); the first chain drive includes a first plurality of sprockets (652, 654) that drive the first continuous chain; (b) said second gear system (672, 674) a second plurality of planetary gear sets, each of said second plurality of planetary gear sets including a second sun gear (641, 615), a second plurality of planet gears (645, 617), and a second ring gear (619, 648, 625, 646); a second plurality of carrier gears (660) attached to said second continuous chain; the second ring gear is in mechanical communication with the second plurality of carrier gears that follow along the path of a second continuous chain (676); the second chain drive includes a second plurality of sprockets (672, 674) that drive the second continuous chain; (c) further comprising: a first plurality of rails (662, 664, 666, 668) that at least partially house and guide the first continuous chain; a second plurality of rails (682, 684, 686, 688) that at least partially receive and guide the second continuous chain, (d) the first plurality of rails guide the first plurality of movable carriers so that each first carrier is substantially parallel to the loading arm (220, 640, 930) when the first chain drive is moving; the second plurality of rails guide the second plurality of movable carriers such that each of the second carriers is substantially parallel to the load arm when the second chain drive is moving; the first plurality of planetary gears cooperate with the first ring gear to guide the first plurality of movable carriers so that each of the first plurality of carriers is substantially parallel to the loading arm as each of the first plurality of carriers moves around the first ring gear; the second plurality of planetary gears cooperate with the second ring gear to guide the second plurality of movable carriers so that each of the second plurality of carriers is substantially parallel to the loading arm as each of the second plurality of carriers moves around the second ring gear; 16. The method of claim 15.

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