Manufacturing system and method for manufacturing an assembly including a tap

Abstract

To improve the certainty of manufacture of an assembly including a tap.SOLUTION: A control part (20) of a manufacturing system (1) of an assembly including a tap allows a robot (10) to execute the steps of: gripping a cap (23) having an opening (H3), engaging the cap (23) with a collet (22) having a recess (H2) so as to cover the collet (22), and thereby preparing a first assembly (A1); gripping the first assembly, and inserting the first assembly into a recess (H1) of a tap holder (21), and thereby preparing a second assembly (A2); and gripping a tap, passing the tap through the opening of the cap of the second assembly, and inserting the tap into the recess of the collet, and thereby preparing a third assembly (A0) as an assembly including the tap.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a manufacturing system and method for producing an assembly for attachment to a machine tool, the assembly including a tap. [Background technology]

[0002] Machine tools that perform tapping are known (see Patent Document 1). Here, taps are often replaced during processing to accommodate tapped holes of different diameters. In this case, an assembly including the tap is generally used to facilitate tap replacement. That is, an operator creates an assembly including the tap by attaching the tap to a tap holder, and then attaches this assembly to the machine tool.

[0003] However, it is not always easy for workers to quickly and accurately assemble a tap assembly. For example, the tap may fall and break during installation, the diameters may not match, or the tap may damage the tap holder when attempting to assemble the tap and tap holder. While such losses can be reduced by skilled workers working carefully, this is not necessarily desirable in terms of work efficiency. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-24487 Summary of the Invention [Problem to be solved by the invention]

[0005] An object of one aspect of the present invention is to provide a system and method for manufacturing an assembly that improves the reliability of manufacturing an assembly that includes a tap. [Means for solving the problem]

[0006] In order to solve the above-mentioned problems, one aspect of the present invention provides a manufacturing system for an assembly including a tap, comprising a robot and a control unit. The robot has a chuck and an arm. The arm is connected to the chuck and moves the chuck. The control unit controls the robot. The control unit causes the robot to perform the steps of creating a first assembly, creating a second assembly, and creating a third assembly. The first assembly includes a cap having an opening, with a recess of a collet positioned within the opening. The step of creating the first assembly includes gripping a cap having an opening with the chuck and engaging the cap so as to cover a collet having a recess. The second assembly includes a collet that engages with the cap, and inserting the collet into the recess of a tap holder. The step of creating the second assembly includes gripping the first assembly with the chuck and inserting the first assembly into the recess of the tap holder. The third assembly is an assembly including a tap. The step of creating the third assembly includes gripping a tap with the chuck and inserting the tap into the recess of the collet through the opening of the cap of the second assembly. [Effects of the Invention]

[0007] According to one aspect of the present invention, it is possible to provide a system and method for manufacturing an assembly that improves the reliability of manufacturing an assembly that includes a tap. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a diagram illustrating a system for manufacturing an assembly including a tap according to an embodiment of the present invention. [Figure 2] FIG. 2 is an exploded perspective view showing the assembly in a disassembled state. [Figure 3] FIG. [Figure 4] FIG. 1 is a flow diagram illustrating a process for manufacturing an assembly. [Figure 5] FIG. 10 is a diagram showing the assembly during manufacture. [Figure 6] FIG. 10 is a diagram showing the assembly during manufacture. [Figure 7] FIG. 10 is a diagram showing the assembly during manufacture. [Figure 8] FIG. 10 is a diagram showing the assembly during manufacture. [Figure 9] FIG. 10 is a diagram showing the assembly during manufacture. [Figure 10] FIG. 10 is a flow chart showing a procedure for creating an assembly based on forces and moments detected by a force sensor. DETAILED DESCRIPTION OF THE INVENTION

[0009] [Embodiment] An embodiment of the present invention will be described in detail below. Fig. 1 is a diagram showing a manufacturing system 1 for an assembly including a tap according to an embodiment of the present invention. The manufacturing system 1 for an assembly including a tap has a robot 10 installed on a table T, and manufactures an assembly including a tap (an assembly A0 described below). An XYZ coordinate system is set, with two directions parallel to the main surface of the table T and perpendicular to each other as the X-axis and Y-axis, and a direction perpendicular to the main surface of the table T as the Z-axis.

[0010] First, we will explain the assembly including the tap (assembly A0). Figure 2 is an exploded perspective view showing the assembly A0 in a disassembled state. The assembly A0 is composed of a tap holder 21, a collet 22, a cap 23, and a tap 24. As will be described later, assemblies A1 and A2 are produced in order by the robot 10, and finally, the assembly A0 is formed on the simple setter Ba. The assembly A1 is composed of the collet 22 and the cap 23. The assembly A2 is composed of the assembly A1, the collet 22, and the tap holder 21. The assembly A0 is composed of the assembly A2 and the tap 24.

[0011] FIG. 3 is a cross-sectional view of the assembly A0. The tap holder 21, collet 22, cap 23, and tap 24 are assembled together. The tap holder 21 has a generally cylindrical projection T and a generally inverted truncated cone recess H1. The collet 22 has a generally inverted truncated cone outer periphery and a generally cylindrical recess H2. The cap 23 is generally cylindrical, has a generally circular opening H3, and an internal space with a larger diameter than the opening H3. The collet 22 is positioned relative to the tap holder 21 such that the outer periphery of the collet 22 is aligned with the inner periphery of the recess H1 of the tap holder 21. The cap 23 covers the projection T of the tap holder 21 and has an engagement portion K2 that engages with the engagement portion K1 of the collet 22. The tap 24 has a generally cylindrical shape and is inserted into the recess H2 of the collet 22.

[0012] 1, the robot 10 is placed on a table T, and includes a base 11, arms 12 to 15, a chuck mechanism 16, a chuck 17, a force sensor 18, and a control unit 20.

[0013] Arms 12 to 15 are connected in sequence to base 11. Arms 12 to 15 are connected to chuck mechanism 16 (ultimately, chuck 17) and can move chuck mechanism 16 (chuck 17) to a desired location. That is, arm 12 can rotate left and right relative to base 11, and arms 12 and 13, arms 13 and 14, and arms 14 and 15 can rotate relative to one another. As a result, arms 12 to 15 can appropriately adjust the position (e.g., the distance of chuck 17 from base 11, the height of chuck 17 from table T) and inclination (e.g., the axial angle of chuck mechanism 16 and chuck 17 relative to the Z axis) of chuck mechanism 16 (chuck 17). Arm 15 can also rotate chuck mechanism 16.

[0014] The chuck 17 can appropriately grip and release a member. The chuck mechanism 16 drives the chuck 17 to open and close.

[0015] The force sensor 18 detects the forces F (Fz, Fy, Fz) and moments M (Mx, My, Mz) applied to the chuck mechanism 16 (chuck 17) during assembly. The moments Mx, My, and Mz are moments around the X-axis, Y-axis, and Z-axis, respectively, and the forces Fx, Fy, and Fz are forces in the X-axis, Y-axis, and Z-axis directions, respectively.

[0016] The control unit 20 controls the robot 10 (arms 12 to 15, chuck mechanism 16) to manufacture (assemble) the assembly A0. That is, the robot 10 sequentially executes the following steps (1) to (3). This enables reliable manufacture of the assembly A0. (1) A step of preparing an assembly A1 (first assembly) in which the cap 23 (having an opening H3) is gripped by the chuck 17 and engaged with the collet 22 (having a recess H2) so that the recess H2 is disposed within the opening H3. (2) A process of gripping the assembly A1 with the chuck 17 and inserting it into the recess H1 of the tap holder 21, thereby creating an assembly A2 (second assembly) in which the collet 22 engaged with the cap 23 is inserted into the recess H1 of the tap holder 21. (3) A step of gripping the tap 24 with the chuck 17 and inserting it into the recess H2 of the collet 22 through the opening H3 of the cap 23 of the assembly A2 to prepare the assembly A0 (a third assembly that is an assembly including the tap).

[0017] An assembly A4 (tap holder 21 covered with cap 23) inserted into a mounting hole Ha of a simple setter Ba, a tap 24 inserted into a mounting hole Hb of a tap stand Bb, and a collet 22 inserted into a mounting hole Hc of a collet stand Bc are arranged on table T. As will be described later, the robot 10 manufactures an assembly A0 using the parts (assembly A4, tap 24, collet 22) held by the simple setter Ba, tap stand Bb, and collet stand Bc.

[0018] On table T, there are arranged assembly A4 (tap holder 21 with cap 23), component holder Sa that holds tap 24, and component holder Sb that holds collet 22. As will be described later, an operator places assembly A4, tap 24, and collet 22 on simple setter Ba, tap stand Bb, and collet stand Bc using tap holder 21, tap 24, and collet 22 held by component holders Sa and Sb.

[0019] Fig. 4 is a flow diagram showing the steps of manufacturing the assembly A0. Figs. 5 to 9 are diagrams showing the assembly A0 in the process of being manufactured. Figs. 4 to 9 are used to show the steps of manufacturing the assembly A0.

[0020] A. Preparation process by workers Steps S1 to S3 are preparation steps performed by an operator, and are performed as a preliminary step before the manufacturing process by the robot 10. That is, the operator installs the assembly A4 (tap holder 21 with cap 23) on the simple setter Ba (step S1). That is, the tip of the tap holder 21 is inserted into the mounting hole Ha of the simple setter Ba, and then the cap 23 is placed on the protruding portion T of the tap holder 21. The operator also installs a tap 24 on a tap stand Bb (step S2). That is, the tap 24 is inserted into the mounting hole Hb of the tap stand Bb. The operator also installs a collet 22 on a collet stand Bc (step S3). That is, the collet 22 is inserted into the mounting hole Hc of the collet stand Bc. At this time, the order of steps S1 to S3 does not matter. Also, steps S1 to S3 may be performed in parallel.

[0021] Here, there is no engagement relationship between the mounting hole Ha and the tap holder 21, between the tap holder 21 and the cap 23, between the mounting hole Hb and the tap 24, or between the mounting hole Hc and the collet 22. Therefore, the worker does not need to make delicate adjustments when inserting the tap holder 21 or the like into the mounting hole Ha or the like and covering the tap holder 21 with the cap 23. In other words, these operations do not require skill and can be performed easily and quickly.

[0022] B. Manufacturing process by robot 10 Thereafter, the manufacturing process (steps S4 to S7) is carried out by the robot 10. This manufacturing process can be divided into the following steps (1) to (3). Figures 5 to 9 are diagrams showing the assembly A0 in the process of being manufactured.

[0023] (1) Creating assembly A1 The robot 10 grips with the chuck 17 the cap 23 of the assembly A4 (the tap holder 21 covered with the cap 23) held by the simple setter Ba and removes it (step S4, FIG. 5). The robot 10 then uses the chuck 17 to engage the removed cap 23 so that it covers the collet 22 (having a recess H2) held by the collet stand Bc, thereby creating the assembly A1 (step S5, FIGS. 6 and 7). In the assembly A1, the collet 22 and the cap 23 are engaged with each other by the engaging portions K1 and K2, and the recess H2 of the collet 22 is visible through the opening H3 of the cap 23.

[0024] (2) Creating assembly A2 The robot 10 grips the assembly A1 held by the collet stand Bc with the chuck 17. Then, the robot 10 inserts the assembly A1 into the recess H1 of the tap holder 21 held by the simple setter Ba using the chuck 17, thereby creating an assembly A2 (step S6, FIG. 8). The assembly A2 is an assembly in which the collet 22 that engages with the cap 23 is inserted into the recess H1 of the tap holder 21. This tap holder has had the cap 23 removed in step S4. In step S6, the tap holder 21 from which the cap 23 was removed in step S4 can be used. As described above, in the assembly A1, the collet 22 and the cap 23 are engaged with each other, so when the cap 23 is gripped and lifted with the chuck 17, the collet 22 can also be lifted at the same time.

[0025] (3) Creating assembly A0 The robot 10 grips and removes the tap 24 held by the tap stand Bb with the chuck 17. Then, the robot 10 inserts the tap 24 into the recess H2 of the collet 22 using the chuck 17 through the opening H3 of the cap 23 of the assembly A2 held by the simple setter Ba. In this way, the robot 10 creates the assembly A0, which is an assembly including the tap (step S7, FIGS. 9 and 3).

[0026] The assembly A0 is manufactured in the above manner. Using this assembly A0, the tap 24 can be easily attached to a processing device.

[0027] Here, in steps S5 to S7, the robot 10 executes the process of creating assemblies A1, A2, and A0 based on the forces and moments detected by the force sensor 18. This improves the reliability of manufacturing the assembly A0. Figure 10 is a flow diagram showing the procedure for creating assemblies A1, A2, and A0 based on the forces and moments detected by the force sensor 18.

[0028] In each of the processes (steps S5 to S7) for producing assemblies A1, A2, and A0, a part (cap 23, assembly A1, or tap 24) is attached to an attachment target (collet 22, tap holder 21, or assembly A2) (step 11). At this time, moment M (Mx, My, Mz) is detected by force sensor 18 (step 12). Basically, assemblies A1, A2, and A0 are produced so that force F or moment M detected by force sensor 18 does not exceed a predetermined threshold value (Th1, Th2) (steps S13 to S16). This improves the reliability of the production of assembly A0.

[0029] Specifically, when the moment M detected by the force sensor 18 exceeds a predetermined threshold value Th1, the tilt of the chuck 17 is adjusted (steps S13 and S14) to align the axes of the part and the object to be attached. This prevents, for example, the tap 24 from damaging the collet 22.

[0030] Furthermore, when the force detected by the force sensor 18 becomes equal to or greater than a predetermined threshold value Th2, the movement (lowering) of the chuck in the direction of the force is stopped (steps S15, S16). In other words, it can be determined that the attachment of the component is complete.

[0031] As described above, in this embodiment, the parts are attached to the simple setters Ba to Bc, which is relatively easy, manually. Then, the robot 10 equipped with the force sensor 18 attaches the parts to the attachment targets. This allows the assembly A0 including the tap 24 to be manufactured efficiently and without error.

[0032] The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in different embodiments are also included in the technical scope of the present invention. [Explanation of symbols]

[0033] 1... Manufacturing system for assembly including tap, 10... Robot, 12 to 15... Arm, 16... Chuck mechanism, 17... Chuck, 18... Force sensor, 20... Control unit, 21... Tap holder, 22... Collet, 23... Cap, 24... Tap, A0, A1, A2... Assembly

Claims

1. a robot having a chuck, an arm connected to the chuck for moving the chuck, and a force sensor for detecting a force or moment applied to the chuck; a control unit that controls the robot, The control unit controls the robot based on the force and moment detected by the force sensor. a step of gripping a cap having an opening with the chuck and engaging the cap so as to cover a collet having a recess, thereby creating a first assembly in which the recess is disposed within the opening; a step of gripping the first assembly with the chuck and inserting it into a recess of a tap holder to create a second assembly in which the collet that engages with the cap is inserted into the recess of the tap holder; a step of gripping a tap with the chuck and inserting the tap through the opening in the cap of the second assembly and into the recess in the collet, thereby creating a third assembly that is an assembly including the tap; Execute A system for manufacturing an assembly including a tap.

2. The step of creating the first assembly includes: and a step of gripping the cap with the chuck and removing it from a fourth assembly, which is the tap holder covered with the cap; The system for manufacturing an assembly including a tap according to claim 1 , wherein the removed cap is gripped by the chuck and engaged to cover the collet.

3. 3. The system for manufacturing an assembly including a tap according to claim 2, wherein in the step of creating the second assembly, the robot grasps the first assembly with the chuck and inserts it into the recess of the tap holder from which the cap has been removed.

4. 4. The system for manufacturing an assembly including a tap according to claim 1, wherein the control unit executes a process of creating the first, second, or third assembly so that the force or moment detected by the force sensor does not exceed a predetermined threshold.

5. 5. The system for manufacturing an assembly including a tap according to claim 4, wherein the control unit adjusts the inclination of the chuck when the moment detected by the force sensor becomes equal to or greater than the predetermined threshold value.

6. 5. The system for manufacturing an assembly including a tap according to claim 4, wherein the control unit stops movement of the chuck in the direction of the force when the force detected by the force sensor becomes equal to or greater than the predetermined threshold value.

7. A manufacturing method for manufacturing an assembly including a tap using a robot having a chuck, an arm connected to the chuck for moving the chuck, and a force sensor for detecting a force or moment applied to the chuck, the method comprising: Based on the force and moment detected by the force sensor, a step of gripping a cap having an opening with the chuck and engaging the cap so as to cover a collet having a recess, thereby creating a first assembly in which the recess is disposed within the opening; a step of gripping the first assembly with the chuck and inserting it into a recess of a tap holder to create a second assembly in which the collet that engages with the cap is inserted into the recess of the tap holder; a step of gripping a tap with the chuck and inserting the tap through the opening in the cap of the second assembly and into the recess in the collet, thereby creating a third assembly that is an assembly including the tap; having A method for manufacturing an assembly including a tap.

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