Assembly system and assembly method

Abstract

To weld first and second members at various angles, and make them flow onto a welded surface without sagging of the welded members downward.SOLUTION: An ultrasonic welding device is provided with: a first robot having a holding part rotatably and tiltably holding a first member and a moving part moving the robot itself; and a welding body part where a second member is disposed on the first member held by the holding part of the first robot, and performing welding by giving vibration by an ultrasonic horn to the first and second members.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to an ultrasonic welding apparatus, an assembly system, and an assembly method for performing ultrasonic welding.

Background Art

[0002] An ultrasonic welding apparatus that performs welding by applying vibration to a first and a second member with an ultrasonic horn is known (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the above ultrasonic welding apparatus, for example, when welding the first and second members at various angles, a complex dedicated machine may be required. Further, when the ultrasonic horn is pressed against the side surfaces of the first and second members to apply vibration, there is a risk that the melted member will droop downward.

[0005] The present disclosure has been made to solve such problems, and a main object thereof is to provide an ultrasonic welding apparatus, an assembly system, and an assembly method capable of welding the first and second members at various angles and pouring the melted member onto the welding surface without drooping downward.

Means for Solving the Problems

[0006] One aspect of the present disclosure for achieving the above object is a first robot having a holding portion that holds a first member rotatably and tiltably, and a moving portion that moves the robot itself; A welding body is provided in which a second member is placed on the first member held by the holding part of the first robot, and welding is performed by applying vibration to the first and second members with an ultrasonic horn, Ultrasonic welding apparatus equipped with That is the case. One aspect of this disclosure for achieving the above objectives is: The ultrasonic welding apparatus described above is provided, The holding part of the first robot holds the welding location of the first member in a horizontal position, and the moving part moves so that the welding location is positioned directly below the ultrasonic horn of the welding body. The second robot holds the second member and places the second member on the welding location of the first member. The welding body performs welding by pressing the ultrasonic horn vertically against the first and second members held by the first and second robots. Assembly system That is the case. On this flight, At least one of the following devices is arranged as a device for the process following the welding: an assembly device for assembling the first and second members, a bolting device for bolting, and an inspection device for inspection. When the first robot completes the work in each process, it may transport the completed component to the next process apparatus and place it in the apparatus, which may then perform work on the component. One aspect of this disclosure for achieving the above objectives is: The above-mentioned assembly method using an ultrasonic welding apparatus, The holding part of the first robot holds the welding location of the first member in a horizontal position, and the moving part moves so that the welding location is positioned directly below the ultrasonic horn of the welding body, The second robot performs the steps of holding the second member and placing the second member on the welding location of the first member, The welding body performs welding by pressing the ultrasonic horn vertically against the first and second members held by the first and second robots, Assembly method including That is the case. [Effects of the Invention]

[0007] The primary objective of this disclosure is to provide an ultrasonic welding apparatus, assembly system, and assembly method that can weld first and second members at various angles and allow molten material to flow onto the welding surface without dripping downwards. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic diagram showing the general configuration of the ultrasonic welding apparatus according to this embodiment. [Figure 2] This diagram shows reference markings provided on the first and second members. [Figure 3] This flowchart shows the flow of the assembly method using the ultrasonic welding apparatus according to this embodiment. [Figure 4] This figure shows a schematic configuration of the assembly system according to this embodiment. [Figure 5] This figure shows an example of a receiving jig according to this embodiment. [Figure 6] This figure shows the variable holding mechanism according to this embodiment. [Modes for carrying out the invention]

[0009] Embodiment 1 This embodiment will be described below with reference to the drawings. The assembly system according to this embodiment includes an ultrasonic welding device for assembling the first and second members by ultrasonic welding. The first and second members are, for example, resin members such as vehicle bumpers and retainers.

[0010] Figure 1 is a schematic diagram showing the general configuration of the ultrasonic welding apparatus according to this embodiment. The ultrasonic welding apparatus 1 according to this embodiment includes a first sensor 2, a first robot 3, a second robot 4, a welding body 5, and a second sensor 6.

[0011] The first robot 3 has a holding part 31 that holds the first member X rotatably and tiltably, and a moving part 32 that moves the robot itself. The holding part 31 is configured as, for example, an articulated arm, and an end effector capable of holding the first member X is provided at the tip.

[0012] The end effector holds the first member X by, for example, suction or gripping. As shown in FIG. 1, for example, the holding part 31 sucks and holds a bumper or the like. The moving part 32 is configured as, for example, a moving carriage that can be moved to a desired position by driving wheels with a motor or the like.

[0013] For example, an operator places the first member X at a predetermined position such as a workbench. The holding part 31 holds the first member X placed at the predetermined position. The first sensor 2 is, for example, a camera that can photograph the first member X at the predetermined position. The holding part 31 holds the first member X while performing position correction based on the image of the first member X acquired by the first sensor 2.

[0014] The moving part 32 moves to the vicinity of the welding main body part 5 with the holding part 31 holding the first member X. Then, the holding part 31 arranges the held first member X on the welding main body part 5.

[0015] At this time, the holding part 31 holds the welding portion X1 of the first member X in a horizontal state, and the moving part 32 moves so that the welding portion X1 is positioned directly below the ultrasonic horn 51 of the welding main body part 5. The second sensor 6 is, for example, a camera that can photograph directly below the ultrasonic horn 51.

[0016] The moving part 32 moves so that the welding portion X1 is positioned directly below the ultrasonic horn 51 of the welding main body part 5 based on the image of the first member X photographed by the second sensor 6. As shown in FIG. 2, the first member X may be provided with a reference marking P for positioning. Thereby, since the position of the first member X can be easily grasped, the positioning time can be shortened, leading to a reduction in man-hours.

[0017] ] As shown in Figure 1, the second robot 4 holds the second member Y and positions the second member Y on the welding location X1 of the first member X. The second robot 4 is configured, for example, as a multi-jointed arm, and is equipped with an end effector at its tip that can hold the second member Y. The base of the second robot 4 is fixed to a mounting base or the like.

[0018] The second robot 4, for example, takes out one second member Y at a time from among several second members Y arranged adjacent to each other and places them on the welding area X1 of the first member X. Based on the images of the first and second members X and Y captured by the second sensor 6, the second robot 4 positions the second member Y on the welding area X1 of the first member X while correcting its position.

[0019] Furthermore, as shown in Figure 2, the second member Y may be provided with reference markings for positioning. This makes it easy to determine the position of the second member Y, thereby reducing positioning time and leading to a reduction in man-hours.

[0020] For example, as shown in Figure 1, the second robot 4 holds the retainer and is positioned on the welding location X1 of the horizontally positioned bumper located on the welding body 5.

[0021] The welding body 5 includes a welding table 52 on which the first and second members X and Y are placed, and an ultrasonic horn 51 that applies ultrasonic vibrations to the first and second members X and Y. The welding body 5 performs ultrasonic welding by pressing the ultrasonic horn 51 vertically against the welding location X1 of the first and second members X and Y on the welding table 52 and applying vibrations to melt and bond the members.

[0022] The first and second robots 3 and 4, and the welding main unit 5, repeat the ultrasonic welding process by changing the welding location X1 of the first member X. When this welding process is completed, the first robot 3 transports the welded first and second members X and Y to the equipment for the next process.

[0023] Incidentally, conventional ultrasonic welding equipment may require a complex, specialized machine when welding, for example, the first and second members at various angles. Also, when an ultrasonic horn is pressed against the sides of the first and second members and vibrated, there is a risk that the molten material will drip downwards.

[0024] In contrast, in the ultrasonic welding apparatus 1 according to this embodiment, as described above, the holding part 31 of the first robot 3 holds the first member X so that it can rotate and tilt, and the moving part 32 moves the robot itself.

[0025] This allows the first and second members X and Y to be welded at various angles. The holding part 31 can hold the welding point X1 of the first member X in a horizontal position, and the moving part 32 can move so that the welding point X1 is positioned directly below the ultrasonic horn 51 of the welding body 5. The welding body 5 then places the second member Y on the first member X held by the holding part 31, and performs welding by applying vibration to the first and second members X and Y with the ultrasonic horn 51. This allows the molten material to flow into the welding surface without dripping downwards.

[0026] Next, an assembly method using the ultrasonic welding apparatus 1 according to the present embodiment will be described. Figure 3 is a flowchart showing the flow of the assembly method using the ultrasonic welding apparatus according to the present embodiment.

[0027] The holding unit 31 of the first robot 3 holds the first member X based on the image of the first member X acquired by the first sensor 2 (step S101).

[0028] The holding part 31 of the first robot 3 holds the welded portion X1 of the first member X in a horizontal position (step S102).

[0029] The moving part 32 of the first robot 3 moves based on the image of the first member X captured by the second sensor 6 so that the welding point X1 is positioned directly below the ultrasonic horn 51 of the welding body 5 (step S103).

[0030] The holding unit 31 may keep the welding location X1 of the first member X in a horizontal position, while the moving unit 32 may move based on the image of the first member X captured by the second sensor 6 so that the welding location X1 is positioned directly below the ultrasonic horn 51 of the welding body 5.

[0031] The second robot 4 positions the second member on the welding site X1 of the first member X based on images of the first and second members captured by the second sensor 6 (step S104).

[0032] The welding body 5 performs ultrasonic welding by pressing the ultrasonic horn 51 vertically against the first and second members X and Y on the welding table 52 and applying vibration to melt the members and bond them together (step S105).

[0033] Embodiment 2 In the assembly system 10 according to this embodiment, at least one of the following devices may be arranged as a device for the process following welding, with respect to the first and second members X and Y: an assembly device for assembling, a bolting device for bolting, and an inspection device for inspection. The assembly device includes a pressing device for pressing parts, an insertion device for inserting parts, a snapping device for snapping parts, and so on.

[0034] When the work in each process is completed, the first robot 3 may transport the completed component to the device for the next process and place it in that device. The device then performs work on the placed component. In this way, by combining each process, and by having the first robot 3 hold the component in each process and transport it between processes, the entire assembly of the component can be automated.

[0035] Figure 4 shows a schematic configuration of the assembly system according to this embodiment. For example, as shown in Figure 4, the pressing device 11 is arranged as the first step. The ultrasonic welding device 1 is arranged as the next second step. The snapping device 12 is arranged as the next third step. The bolt tightening device 13 is arranged as the next fourth step. The assembly device 14 is arranged as the next fifth step. The inspection device 15 is arranged as the next sixth step.

[0036] For example, the first robot 3 holds the workpiece and moves to the front of the pressing device 11 for the first step. The pressing device 11 performs a pressing operation on the workpiece held by the first robot 3 as the first step. When the pressing operation of the first step is completed, the first robot 3 holds the workpiece that has been pressed and moves to the front of the ultrasonic welding device 1 for the second step. The ultrasonic welding device 1 performs a welding operation on the workpiece held by the first robot 3 as the second step. When the welding operation of the second step is completed, the first robot 3 holds the workpiece that has been welded and moves to the front of the snapping device 12 for the third step.

[0037] In the third step, the snapping device 12 performs a snapping operation on the member held by the first robot 3. Once the snapping operation of the third step is completed, the first robot 3 holds the member after the snapping operation is completed and moves to the front of the bolting device 13 for the fourth step. In the fourth step, the bolting device 13 performs a bolting operation on the member held by the first robot 3. Once the bolting operation of the fourth step is completed, the first robot 3 holds the member after the bolting operation is completed and moves to the front of the assembly device 14 for the fifth step.

[0038] As the fifth step, the assembly device 14 performs assembly work on the component held by the first robot 3. When the assembly work of the fifth step is completed, the first robot 3 holds the assembled component and moves it to the front of the inspection device 15 for the sixth step. As the sixth step, the inspection device 15 performs inspection work on the component held by the first robot 3. When the inspection work of the sixth step is completed, the first robot 3 holds the inspected component and carries it away.

[0039] Furthermore, a robot holding each component may be fixed in front of the device for each process. When the work for each process is completed, each robot may hand over the component that has been worked on in that process to the robot for the next process. The robot for the next process holds the handed-over component and places it in the device in front of it, and that device performs work on the placed component.

[0040] Embodiment 3 The welding body 5 of the ultrasonic welding apparatus 1 performs welding by pressing the ultrasonic horn 51 against the first and second members X and Y from above with vibration while the first and second members X and Y are supported by the receiving jig. Figure 5 shows an example of the receiving jig according to this embodiment. As shown in Figure 5, the receiving jig 53 according to this embodiment is configured so that the shape of the receiving surface can be changed to match the shape of the receiving members.

[0041] The receiving jig 53 includes, for example, a first receiving portion 531 formed in a first shape, a second receiving portion 532 formed in a second shape, a third receiving portion 533 formed in a third shape, and a fourth receiving portion 534 formed in a fourth shape. Each of the first to fourth receiving portions 531 to 534 extends radially from the center and has a receiving surface of the first to fourth shape at its tip.

[0042] For example, the first shape is formed as a flat surface, the second shape as a small concave shape, the third shape as a small convex shape, and the fourth shape as a large convex shape. The receiving jig 53 according to this embodiment has four receiving parts, but is not limited to this configuration. The number of receiving parts may be increased or decreased depending on the type of shape of the component being manufactured.

[0043] The receiving jig 53 rotates the first to fourth receiving parts 531 to 534 so that the receiving part that matches the shape of the receiving member is at the 0° position (top position). This allows a single welding body 5 to flexibly change the shape of the receiving parts to accommodate the shapes of multiple members, enabling stable ultrasonic welding and contributing to reduced manufacturing costs.

[0044] Furthermore, the member may be supported by the aforementioned receiving jig while also being held by a variable holding mechanism. Figure 6 shows a variable holding mechanism according to this embodiment. As shown in Figure 6, the variable holding mechanism 54 has a support plate portion 541 that supports the member, and a plurality of expandable / contractable portions 542 that expand and contract in the vertical direction to support the support plate portion 541. Note that in the perspective view, the support plate portion 541 is omitted in order to make the expandable / contractable portions 452 easier to see. The expandable / contractable portions 542 expand and contract by driving an actuator or the like to expand / contract mechanism. As a result, the member can be stably supported by expanding and contracting the expandable / contractable portions 542 according to the shape of the member.

[0045] While several embodiments of the present invention have been described, these embodiments are presented as examples only and are not intended to limit the scope of the invention. These novel embodiments can be carried out in a variety of other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims and their equivalents. [Explanation of Symbols]

[0046] 1 Ultrasonic welding device, 2 First sensor, 3 First robot, 4 Second robot, 5 Welding body, 6 Second sensor, 10 Assembly system, 11 Pressing device, 12 Snap device, 13 Bolt tightening device, 14 Assembly device, 15 Inspection device, 31 Holding part, 32 Moving part, 51 Ultrasonic horn, 52 Welding table, 53 Receiving jig, 54 Holding mechanism, 531 First receiving part, 532 Second receiving part, 533 Third receiving part, 534 Fourth receiving part, 541 Support plate part, 542 Expandable part

Claims

1. A first robot having a holding part that holds a first member so that it can rotate and tilt, and a moving part that moves the robot itself, A welding body is provided in which a second member is placed on the first member held by the holding part of the first robot, and welding is performed by applying vibration to the first and second members with an ultrasonic horn, Equipped with an ultrasonic welding device, The holding part of the first robot holds the welding location of the first member in a horizontal position, and the moving part moves so that the welding location is positioned directly below the ultrasonic horn of the welding body. The second robot holds the second member and places the second member on the welding location of the first member. The welding body is held by the first and second robots, and welding is performed by pressing the ultrasonic horn vertically against the first and second members which are supported by the receiving jig. The receiving jig rotates the receiving portion so that the receiving portion that matches the shape of the first and second members being received is at the top position, thereby changing the shape of the receiving surface of the receiving portion to match the shape of the first and second members being received. Assembly system.

2. The assembly system according to claim 1, At least one of the following devices is arranged as a device for the process following the welding: an assembly device for assembling the first and second members, a bolting device for bolting, and an inspection device for inspection. When the work in each process is completed, the first robot transports the completed component to the next process apparatus and places it in the apparatus, and the apparatus performs work on the component. Assembly system.

3. An assembly method using the assembly system described in claim 1, The holding part of the first robot holds the welding location of the first member in a horizontal position, and the moving part moves so that the welding location is positioned directly below the ultrasonic horn of the welding body, The second robot performs the steps of holding the second member and placing the second member on the welding location of the first member, The welding body performs welding by pressing the ultrasonic horn vertically against the first and second members held by the first and second robots, Assembly method including

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