Automated workpiece threading systems and related methods

Abstract

A method for threading workpieces in an automated mass production system includes (a) advancing a carrier holding at least one first workpiece along a transport track to a stop position. Each first workpiece has first threading extending about a first axis. The method further includes (b) advancing at least one second workpiece to an unloading position. Each second workpiece has second threading extending about a second axis. The method further includes (c) operating an effector to move the second workpiece toward the stop position to bring the second axis of the second workpiece into coaxial alignment with the first axis of a respective first workpiece, and (d) when the first and second axes are in coaxial alignment, operating the end effector to thread the first and second threading together through rotation and advancement of the second workpiece relative to the first workpiece.

Description

TITLE: AUTOMATED WORKPIECE THREADING SYSTEMS AND RELATED METHODSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 585,477 filed on September 26, 2023, which is hereby incorporated herein by reference in its entirety.FIELD

[0002] The present disclosure relates to systems and methods for threaded assembly of workpieces in an automated mass production process.BACKGROUND

[0003] U.S. Pat. 9,904,281 (Nicholson et al.) discloses an automated method of assembling or processing components using computer numerical controlled drives to decouple the stages of delivering components to a tool, into a series of separately programmable stages, namely, a component loading stage, a component separating stage, an accelerating stage, and a delivery stage, wherein the timing, position, speed, velocity, and acceleration of each component during each stage is selected through programming of the computer numerical controls.

[0004] U.S. Pat. 10,018,985 (Nicholson et al.) discloses a device, system and method of automated manufacture comprising: delivering a workpiece with a delivery device; receiving the workpiece with a receiving device, the delivering of the workpiece and the receiving of the workpiece being electronically synchronized; processing the workpiece with a processing tool while the workpiece is on the receiving device; transferring the workpiece to a completion device, the ejection of the workpiece and the transferring of the workpiece being electronically synchronized. In particular the workpiece may comprise: a platform with mounts supporting a first component in a selected orientation; and a locating surface, the method comprising: engaging and disengaging the locating surface of the workpiece with releasable connectors on the delivery device, on the receiving device and on the completion device.SUMMARY

[0005] The following summary is intended to introduce the reader to various aspects of the applicant’s teaching, but not to define any invention.

[0006] According to some aspects, a method of threading workpieces in an automated mass production process includes: (a) advancing a carrier along a transport track to a stop position, the carrier holding at least one first workpiece, each first workpiece having first threading extending about a first axis; (b) advancing at least one second workpiece to an unloading position spaced apart from the transport track, each second workpiece having second threading extending about a second axis, the second threading complementary to the first threading for forming a threaded connection between the first and second workpieces; (c) operating at least one end effector to move the second workpiece from the unloading position toward the stop position to bring the second axis of the second workpiece into coaxial alignment with the first axis of a respective first workpiece at the stop position; and (d) when the first and second axes are in coaxial alignment, operating the end effector to thread the first and second threading together through rotation and advancement of the second workpiece relative to the first workpiece for assembling the first and second workpieces in the carrier.

[0007] In some examples, (c) includes operating a gripper of the end effector to grip the second workpiece, and (d) includes rotating the gripper about the second axis and advancing the gripper along the first axis while gripping the second workpiece.

[0008] In some examples, the first and second axes are oriented vertically during (d).

[0009] In some examples, each first workpiece projects upwardly from the carrier along the first axis, and the method further includes holding each first workpiece at the stop position between a pair of arms of a workpiece alignment mechanismto hold the first axis at a predetermined position and orientation for coaxial alignment with the second axis.

[0010] In some examples, the method includes moving the pair of arms relative to each other from an open position, in which the pair of arms are spaced apart from each other for receiving each first workpiece at the stop position between the pair of arms, to a closed position in which the pair of arms are moved toward each other relative to the open position to hold the first workpiece therebetween.

[0011] In some examples, the first workpiece is received in a respective groove formed between the pair of arms in the closed position.

[0012] In some examples, movement of the pair of arms from the open position toward the closed position is initiated during deceleration of the carrier toward the stop position.

[0013] In some examples, the method includes, after initial thread engagement between the first and second threading during (d), moving the pair of arms from the closed position toward the open position to accommodate movement of the end effector downwardly between the pair of arms for advancement of the second workpiece relative to the first workpiece during (d).

[0014] In some examples, the method includes, during movement of the second workpiece toward the stop position in (c), operating the end effector to rotate the second workpiece for aligning a thread start of the second threaded portion with that of the first threaded portion.

[0015] In some examples, each second workpiece is loaded onto a respective retainer of an indexing device prior to (c), and (b) includes advancing the retainer toward the unloading position.

[0016] In some examples, the method includes, after (d), (e) operating the end effector to release the second workpiece and advancing the carrier away from the stop position, and repeating (a) to (e) for threading together subsequent first and second workpieces in a continuous automated mass production process.

[0017] In some examples, the at least one end effector comprises a plurality of end effectors for picking up a plurality of respective second workpieces from the unloading position and threading the plurality of respective second workpieces onto a plurality of respective first workpieces at the stop position.

[0018] According to some aspects, an automated mass production system for threading workpieces includes: (a) a track including a plurality of carriers, each carrier holding at least one first workpiece and advanceable to a stop position along the track, each first workpiece having first threading extending about a first axis; (b) an indexing device having a plurality of retainers, each retainer advanceable from a loading position for receiving a respective second workpiece to an unloading position spaced apart from the loading position for unloading of the second workpiece from the retainer, each second workpiece having second threading extending about a second axis, the second threading complementary to the first threading for forming a threaded connection between the first and second workpieces; and (c) a pick-and-place robot having at least one end effector movable between a pick-up position adjacent the unloading position for pick-up of the second workpiece from the indexing device, and a threading position adjacent the stop position for coaxial alignment of the second axis of the second workpiece picked up by the end effector with the first axis of the first workpiece at the stop position, and when in the threading position, the end effector is operable to rotate the second workpiece about the second axis while advancing the second workpiece along the first axis to thread together the first and second threading for assembling the first and second workpieces in the carrier.

[0019] In some examples, the production system includes (d) a workpiece alignment mechanism adjacent the stop position and operable to hold the first workpiece at the stop position at a predetermined position and orientation to facilitate coaxial alignment of the first axis with the second axis.

[0020] In some examples, the alignment mechanism includes a pair of arms movable transversely relative to the track between an open position in which the arms are spaced apart from each other for receiving the first workpiece arriving atthe stop position between the pair of arms, and a closed position in which the pair of arms are moved toward each other to hold the first workpiece between the pair of arms.

[0021] In some examples, when in the closed position, the pair of arms define at least one groove between the pair of arms, each groove for receiving a respective first workpiece at the stop position.

[0022] In some examples, each groove extends vertically through the pair of arms for orienting the first axis vertically.

[0023] In some examples, the end effector includes a gripper operable to grip the second workpiece at the unloading position for pick up and movement of the second workpiece to the threading position, and to rotate about the second axis while gripping the second workpiece.

[0024] In some examples, the indexing device comprises a rotary table.

[0025] In some examples, the production system includes a control system for synchronizing operation of the carriers, indexing device, pick-and-place robot, and alignment system to perform the methods disclosed herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The drawings included herewith are for illustrating various examples of apparatuses, systems, and processes of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:

[0027] Figure 1 is a schematic of an example automated mass production system;

[0028] Figure 2 is a schematic of an example production device of the system of Figure 1 ;

[0029] Figure 3 is a schematic of an example implementation of the system 100 of Figure 1 ;

[0030] Figure 4 is a schematic showing an example arrangement of a plurality of processing stations of the system of Figure 1 ;

[0031] Figure 5 is a perspective view of an example processing station of Figure 4;

[0032] Figures 6 to 12 are perspective views showing example process steps for threading together workpieces using the station of Figure 5.DETAILED DESCRIPTION

[0033] Various apparatuses, systems, or processes will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover apparatuses, processes, or systems that differ from those described below. The claimed inventions are not limited to apparatuses, systems, or processes having all of the features of any one apparatus, system, or process described below or to features common to multiple or all of the apparatuses, systems, or processes described below. It is possible that an apparatus, system, or process described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus, system, or process described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors, or owners do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document.

[0034] A production process can involve processing (e.g. feeding, indexing, transferring, assembling, threading, transporting, validating, etc.) parts to produce a product. During the production process, the part requiring further processing (for example, a subcomponent, assembly, or partially finished product) can be referred to as a workpiece. The workpiece can be moved through a production system among various production devices that operate on the workpiece(s) in production of the product.

[0035] In some applications, a production process may require threading together of workpieces. According to some aspects of the present disclosure, a workpiece threading system can include a plurality of production devices electronically synchronized to improve efficiency (e.g. speed) of the threading operation. The production devices can include one or more presentation devices (e.g. feed, indexing, and / or transport devices) and one or more processing devices (e.g. pick-and-place and / or threading robots) operable in electronic synchronization with one another to facilitate a workpiece threading process. In some examples, the threading system can include a transport track having a plurality of carriers holding first workpieces advanceable along the track to a stop position and an indexing device having a plurality of second workpieces advanceable to an unloading position. The threading system can include a pick- and-place robot having at least one end effector. The end effector can be operable to engage (e.g. grip) a second workpiece held by the indexing device at the unloading position and translate the second workpiece into alignment with a corresponding first workpiece. The end effector can be rotatable and translatable relative to the first workpiece to thread the first and second workpieces together. According to some aspects of the present disclosure, operation of the carrier, the indexing device, the pick-and-place robot, and a workpiece alignment system can be electronically synchronized for improved processing efficiency relative to some other systems.

[0036] Referring to Figure 1 , a schematic of an example automated production system 100 is shown. In the example illustrated, the production system 100 includes a plurality of production devices 110 for processing workpieces, a production control system 120 for controlling operation of the production devices 110 and / or other system components to facilitate a mass production process, a communication network 130 for enabling communication among system components, and a production system storage component 140 for storing relevant data for the production system 100 (e.g. operational and / or control data relating to the production devices 110 and / or other aspects of the system 100).

[0037] In the example illustrated, the control system 120 includes a control system storage component 122, one or more system processors 124, and a system communication component 126. The system processor 124 controls operation of the control system 120. In some examples, the system processor 124 and processors at the production devices 110 cooperate to control operation of the system 100 (e.g. through determination and / or processing of control parameters and generation of control signals for operation and synchronization based on the control parameters).

[0038] In some examples, the storage component 122 (e.g. memory) can store data received from the production devices 110, data for coordinating operation of the production devices 110, property data in respect of each production device 110, etc. The storage component 122 can store computer programs executable by the system processor 124 to facilitate communication among and operation of the system components.

[0039] The production system storage component 140 can be accessible via the communication network 130 and provided in addition to or in lieu of the control system storage component 122. In some examples, the control system storage component 122 can store current operating data corresponding to current operation of the control system 120 (e.g. current position, speed, velocity, and / or acceleration of production tooling), and the production system storage component 140 can store data for future use. In some examples, the storage component 140 can include third party data storage. The storage component 140 can store information about the production devices 110, including operating data, profile data (e.g., servo-motor profile data), motion data (e.g., tool motion data), part / workpiece / product data, etc. Such data can be stored in the storage component 140 for subsequent retrieval by the production devices 110 and / or control system 120, for example, through download via communication network 130.

[0040] The communication network 130 can carry data to enable communication among system components (e.g. among the control system 120, productiondevices 110, storage component 140, and / or other devices / components), and can be a wired and / or wireless communication network. In some examples, components of the system 100 (including, for example production devices 110 and control system 120) can include wireless communication interfaces to enable wireless communication through communication network 130.

[0041] Referring to Figure 2, a block diagram representing an example production device 110 is shown. In the example illustrated, the production device 110 includes a device control system 220, a sensor system 210, tooling 230, and a motion system 240.

[0042] In the example illustrated, the device control system 220 includes a device processor 224, a device storage component (e.g. memory) 222, and a device communication component 226. The device control system 220 is operable to control operation of the production device 110, and can collect and store sensor, tooling, and motion data for the production device 110 in the device storage component 222 for operational use and / or for providing to the control system 120 through network 130 to facilitate electronic synchronization of production devices 110.

[0043] The device storage component 222 can store data for operation of the production device 110 and / or to facilitate electronic synchronization. Example data can include, for example, operating data, part data, tool data, motion data, sensor data, etc. The sensor system 210 can include one or more sensors (e.g. rangefinding, motion, vision systems, etc.) for collecting operational and / or environmental data for facilitating the production process. Each production device 110 can be equipped with a motion system 240 for movement of the production device 110 and / or components thereof (e.g. sensors, tooling, etc.). The motion system 240 can include, for example, one or more servo-motors and / or other actuators.

[0044] The production devices 110 can be equipped with tooling 230 for engaging with and processing workpieces. Tooling 230 can be used for, forexample, part handling, manipulation, transport, etc. The operation of tooling 230 can be controlled by the device control system 220 based on, for example, sensor data from the sensor system 210 and operational data for the production device 110 or other production devices 110 and / or system components.

[0045] The tooling 230 can be in the form of, for example, one or more workpiece presentation tools for presenting the workpieces at predetermined locations for delivery and / or further processing and / or one or more workpiece processing tools for performing value-added operations on the workpieces. The workpiece presentation tools can be part of, for example, one or more tracks, carriers, conveyors, screws, indexer, actuators, or other devices for, for example, separating workpieces from other workpieces and delivery of the workpieces to a processing tool for subsequent processing. In some examples, the presentation tools can be part of a carrier and configured to, for example, receive one or more workpieces, accelerate the workpieces toward a stop position (e.g. along a transport track) for a processing station, and present the workpieces at the processing position for processing by one or more processing tools of the station.

[0046] Processing tools can be configured to conduct one or more value-added operations on or with the workpieces. For example, the processing tools can be configured to manipulate a workpiece, assemble (e.g. thread) two or more workpieces together, reorient and / or reposition a workpiece for further processing, etc. In some examples, processing tools can include, e.g. end effectors such as manipulators and / or grippers for part manipulation, assembly, reorientation, rotation, threading, etc. In some examples, the processing tools can be part of a pick-and-place robot and can be configured to, for example, unload one or more second workpieces from a workpiece presentation tool (e.g. of an indexing device); align the second workpiece with a corresponding first workpiece; and thread the first and second workpieces together to assemble the first and second workpieces in a workpiece presentation tool (e.g., a carrier).

[0047] Machine-readable instructions stored in storage component 222 (or in storage 122, 140) can cause the control system 220 (and / or 120) to executevarious methods disclosed herein including generation of one or more signals (e.g., output data) useful in operation of the production devices 110. Such machine-readable instructions can be incorporated into one or more computer program products which can be stored on suitable medium or media. In some embodiments, the machine-readable instructions can be executable by processor 224 and / or 124 for generation of signals useful in electronic synchronization of two or more operations carried out by the tooling 230 (e.g. by presentation and processing tools) of the production devices 110. The machine-readable instructions can be executable by the processor(s) for determination and / or selection of control parameters for operation of the tooling 230 and generate signals representative of the control parameters. For example, the machine- readable instructions can be configured to cause processor 224 and / or 124 to generate signals useful in the electronic synchronization of, for example, the delivery of workpieces by a presentation tool and receipt of the workpieces by a processing tool; the processing steps performed by one or more processing tools; and / or delivery of a workpieces by the processing tool and receipt of the workpieces by the presentation tool.

[0048] The synchronization of two or more operations performed by the tooling 230 of one or more production devices 110 can utilize electronic camming (e.g. instead of mechanical cams, gears, or linkages). In various embodiments, the use of such electronic synchronization can facilitate system flexibility and improve system performance relative to some more-conventional systems utilizing mechanical synchronization means. In some examples, storage component 222 (and / or 122, 140) can hold data representative of one or more cam profiles to be used in the operation of the tooling 230 of one or more production devices 110. For example, such cam profile(s) can be in tabular form and can include corresponding positions representative of synchronized trajectories to be followed by the tooling 230 during operation. In some examples, one tooling component 230 can be operated as a master device and another tooling component 230 can be operated as a slave device executing movements based on the execution ofmovements by the master device in order to substantially maintain synchronization between the slave device and the master device. In some examples, the production devices 110 can include one or more master devices and one or more respective slave devices. For example, multiple slave devices can be electronically cammed with a master device.

[0049] The machine-readable instructions can be configured to cause processor 224 and / or 124 to generate signals useful in electronic synchronization (e.g. camming) of the delivery of a workpiece by a presentation tool and of receipt of the workpiece by a processing tool (or another presentation tool). In some embodiments, the machine-readable instructions can be configured to cause the processor(s) to generate signals useful in electronic synchronization of loading, separation, acceleration, and delivery of a workpiece by a presentation tool and of receipt of the workpiece by a processing tool. In some embodiments, the machine- readable instructions can be configured to cause the processor(s) to generate signals useful in controlling movement of a workpiece along a delivery trajectory and controlling movement of a processing tool along a processing tool trajectory for electronic synchronization of the workpiece and processing tool.

[0050] In some examples, the machine-readable instructions can be configured to cause processor 224 and / or 124 to generate signals useful in controlling at least some aspect of the processing of a workpiece. For example, such processing can include one or more value-added operations that can be carried out by the processing tool. Such value-added operation can include, for example, threading together of two or more workpieces. The machine-readable instructions may, for example, be configured to cause processor 224 (and / or 124) to generate signals useful in electronic synchronization of the processing of a workpiece and one or more operations associated with presentation and / or processing tools. In some embodiments, the machine-readable instructions can be configured to cause the processor(s) to generate signals for controlling advancement of an indexing device holding one or more second workpieces and movement of an end-effector for electronic synchronization of the advancement of the indexing device andmovement of the end-effector to pick up the one or more workpieces from the indexing device. In some embodiments, the machine-readable instructions can be configured to cause the processor(s) to generate signals for controlling advancement of a carrier holding one or more first workpieces and movement of a workpiece alignment mechanism for alignment of the one or more first workpieces held by the carrier for electronic synchronization of the carrier and workpiece alignment mechanism. In some embodiments, the machine-readable instructions can be configured to cause the processor(s) to generate signals for controlling advancement of the carrier holding the one or more first workpieces and movement of the end-effector holding one or more second workpieces for electronic synchronization of the advancement of the carrier and movement and rotation of the end-effector to thread the one or more second workpieces held by the endeffector onto the one or more first workpieces in the carrier. In some examples, the machine-readable instructions can be configured to cause the processor(s) to generate signals for controlling advancement and rotation of the end effector for threading the one or more second workpieces onto the one or more first workpieces and movement of the workpiece alignment mechanism toward an open position to accommodate further advancement of the end effector between arms of the workpiece alignment mechanism for electronic synchronization of the advancement / rotation of the end effector with the movement of the workpiece alignment mechanism. In some examples, one or more operations conducted by the presentation or processing tools can be under binary control rather than direct electronic synchronization. In some examples, the triggering of an operation via a binary control signal can be dependent on the position of a master device and can still be based on a cam profile. The production devices 110 can include one or more servo-motors associated with tooling components 230, and the machine- readable instructions can be configured to cause processor 224 and / or 124 to generate signals useful in controlling the servo-motors according to a predetermined cam profile to carry out electronically synchronized operations according to the methods herein.

[0051] The production devices 110 can include a numerically synchronized control architecture. For example, transfer and presentation of workpieces (e.g. by presentation tools) according to the methods disclosed herein can include a first computer numerically controlled operation and the receiving of the workpiece (e.g. by a processing tool or another presentation tool) can include a second computer numerically controlled operation. In some examples, the loading, separating, accelerating, and delivering of workpieces can include a first computer numerically controlled operation and the receiving of the workpieces can include a second computer numerically controlled operation. In some examples, the receiving of a workpiece can include a first computer numerically controlled operation and the processing of the workpiece can include a second computer numerically controlled operation. In some examples, the processing of a workpiece can include a first computer numerically controlled operation and the delivery of the workpiece can include a second computer numerically controlled operation. In some examples, advancement of an indexing device holding one or more second workpieces can include a first computer numerically controlled operation and movement of the endeffector to pick up the one or more workpieces from the indexing device can include a second computer numerically controlled operation. In some examples, the advancement of a carrier with one or more first workpieces to a stop position can include a first computer numerically controlled operation and the movement of a workpiece alignment mechanism toward a closed position for alignment of the one or more first workpieces at the stop position can include a second computer numerically controlled operation. In some examples, advancement of the carrier holding the one or more first workpieces can include a first numerically controlled operation and movement of the end-effector holding one or more second workpieces for threading onto the first workpieces can include a second computer numerically controlled operation. In some examples, advancement and rotation of the end effector for threading the one or more second workpieces onto the one or more first workpieces can include a first computer numerically controlled operation and movement of the workpiece alignment mechanism toward an open position toaccommodate further advancement and rotation of the end effector between arms of the workpiece alignment mechanism can include a second computer numerically controlled operation. In such examples, the first computer numerically controlled operation and the second computer numerically controlled operation can be electronically synchronized (e.g. electronically cammed).

[0052] Referring to Figure 3, an example implementation 100a of the system 100 is shown schematically. The example system 100a can be configured to carry out steps from processes disclosed herein. System 100a can receive workpieces and / or raw materials as inputs; progressively add value to them via processing tools; and discharge them either as discrete finished products, as unfinished products, or as rejected scrap (i.e. , defective products).

[0053] As shown in Figure 3, system 100a can receive the workpieces and / or materials from one or more feeders (e.g. of a feed device) for delivering workpieces and / or materials to another presentation tool (e.g. of an indexing device). The delivery from the feeders can be done directly or via a respective buffer. Each presentation tool or transfer device (e.g. carrier) of the system 100a can be numerically controlled and configured to deliver the materials and / or workpieces to one or more processing tools (e.g. of a processing device). Each processing tool can add value to a workpiece and / or material via one or more programmable process steps. A given processing tool can operate in parallel to and / or in series with one or more other processing tools and / or presentation tools. Once the workpiece passes through a final processing tool, it can be discharged either as a successfully completed and validated finished product, as an unfinished product, or as rejected scrap. Human interaction with system 100a can be through an operator interface.

[0054] The system can include validation stations including validation devices configured to conduct inspections, checks, and / or tests on one or more of the workpieces. In some examples, the validation stations can be located at, for example, one or more feeders, presentation tools, transfer devices, and / or processing tools. At these points, workpieces can be eliminated from the systemas scrap if they do not meet one or more predetermined inspection criteria. Validation stations can be configured to conduct inspection, check, and / or test operations on one or more of workpieces that can be electronically synchronized with other devices, such as, for example, a master device of the production devices 110.

[0055] The various elements described above can be controlled at least in part by software resources known as base software backplane. The backplane can be configured to permit various elements of the system to carry out various control functions including: management of inputs and outputs; management of local control tasks, including programmable process steps within processing tools and local inspection tasks within validation stations; communications between different elements in the system and communication with a human user via the operator interface.

[0056] The system 100a can include a numerically synchronized control architecture. In various embodiments, the feeders, presentation tools, processing tools, and transfer devices can be numerically controlled. Movement of workpieces and materials through the system can occur along programmable axes of motion, which can be either rotary or linear. Movement of tooling associated with the programmable process steps of processing tools can also take place along programmable linear and / or rotary axes of motion.

[0057] Referring to Figure 4, an example arrangement of production devices 110 of the system 100 is shown schematically. In the illustrated example, the system 100 includes a transport track 150 supporting a plurality of carriers 152. Each carrier 152 comprises a pallet configured for holding at least one first workpiece (e.g. auto-injector / syringe body), and is movable along the track 150 (e.g. through one or more servo-drives) among a plurality of processing stations 160. Each processing station 160 includes one or more production devices 110 operable in electronic synchronization with each other, the carriers 152, and / or production devices 110 of other processing stations 160 for processing the workpieces.

[0058] In the example illustrated, the processing stations 160 shown in Figure 4 include a first processing station 160a for transferring one or more first workpieces 170 to each carrier 152 and a second processing station 160b downstream of the first processing station 160a for delivering and installing (e.g. threading) one or more second workpieces (e.g. dosage dial collars) onto the first workpieces 170 held by the carrier 152 to form a workpiece assembly 170a. The processing stations 160 of the system 100 shown in Figure 4 further include one or more third processing stations 160c downstream of the second processing station 160b for further processing of the workpiece assembly 170a held by the carrier 152 (e.g. repositioning, reorienting, installation of one or more additional parts, validating, testing, inspecting, and / or removing the workpiece assembly from the carrier for discharge from the system 100, either as a successfully completed and validated finished product, as an unfinished product, or as a rejected defective product).

[0059] Referring to Figure 5, an example threading station 300 (e.g. for use as the second processing station 160b in the system 100 shown in Figure 4) is illustrated. In the example illustrated, each carrier 152 holds at least one first workpiece 170 and is advanceable through a stop position along the transport track 150 (only a portion of which is shown in Figure 5) adjacent the threading station 300. In the example illustrated, each carrier 152 holds a pair of first workpieces 170.

[0060] Referring to Figure 8A, in the example illustrated, each first workpiece 170 has first threading 174 extending about a first axis 178. In the example illustrated, the first threading 174 includes external threading formed on an outer surface of the first workpiece 170. In the example illustrated, the first workpiece 170 comprises an elongate auto-injector body projecting upwardly from the carrier 152 along the first axis 178. The first workpiece 170 has a lower portion mounted to the carrier 152 and rotationally fixed thereto, and an upper portion projecting upwardly from the carrier 152. The first threading 174 extends along the upper portion above the carrier 152.

[0061] Referring to Figure 5, in the example illustrated, the threading station 300 includes an indexing device 154 spaced transversely apart from the track 150 and having a plurality of retainers 156. The indexing device 154 is operable to advance each retainer 156 from a loading position for receiving a respective second workpiece 172 (e.g. from a feeder device) to an unloading position spaced apart from the loading position for unloading of the second workpiece 172 from the retainer 156. In the example illustrated, the indexing device 154 is operable to advance a pair of retainers 156 to the unloading position, and position a pair of respective second workpieces 172 at the unloading position. In the example illustrated, the indexing device 154 comprises a rotary table rotatable about a vertical axis for advancing the retainers 156 from the loading position to the unloading position, with the retainers 156 spaced circumferentially apart about the vertical axis.

[0062] Referring to Figure 7A, in the example illustrated, each second workpiece 172 has second threading 176 extending about a second axis 180. The second threading 176 is complementary to the first threading 174 for forming a threaded connection between the first and second workpieces 170, 172. In the example illustrated, the second threading 176 comprises internal threading formed on an inner surface of the second workpiece 172. In the example illustrated, the second workpiece 172 comprises a dosage dial collar for mounting over the outer surface of the auto-injector body. In the example illustrated, the dosage dial collar has a central bore extending along the second axis 180 and along which the second threading 176 is formed.

[0063] Referring to Figure 5, in the example illustrated, the threading station 300 includes a pick-and-place robot 310 between the track 150 and the indexing device 154. The pick-and-place robot 310 has at least one end effector 312. In the example illustrated, the pick-and-place robot 310 includes a pair of end effectors 312 movable together between a pick-up position (shown in Figure 6) adjacent the unloading position for pick-up of the pair of respective second workpieces 172 at the unloading position, and a threading position (shown in Figure 8) adjacent thestop position for coaxial alignment of the second axis 180 of the second workpiece 172 picked up by the end effector 312 with the first axis 178 of the first workpiece 170 at the stop position. When in the threading position, the pair of end effectors 312 are operable to rotate and advance the second workpieces 172 relative to respective first workpieces 170 to thread the first and second threading 174, 176 together for assembling the first and second workpieces 170, 172 in the carrier (e.g. to form the workpiece assemblies 170a).

[0064] In the example illustrated, each end effector 312 includes a gripper 314 operable to grip the second workpiece 172 to facilitate pick up, movement, and threading of the second workpiece 172. In the example illustrated, the gripper 314 is operable to grip the second workpiece 172 at the unloading position for pick up and movement of the second workpiece 172 to the threading position. When at the threading position, the gripper 314 is operable to rotate about the second axis 180 while gripping the second workpiece 172 and advance along the first axis 178 toward the first workpiece 170 at the stop position to facilitate threading of the second workpiece 172 onto the first workpiece 170.

[0065] In the example illustrated, the threading station 300 can include a workpiece alignment mechanism 190 adjacent the stop position. In the example illustrated, the workpiece alignment mechanism 190 is operable to urge the first workpiece 170 at the stop position into a predetermined position and orientation for coaxial alignment of the first axis 178 of the first workpiece 170 at the stop position with the second axis 180 of the second workpiece 172 at the threading position. In the example illustrated, the workpiece alignment mechanism 190 includes a pair of arms 192 movable transversely relative to the track 150 between an open position (shown in Figure 5), in which the arms 192 are spaced apart from each other for receiving the first workpiece 170 arriving at the stop position between the pair of arms 192, and a closed position (shown in Figure 8), in which the pair of arms 192 are moved toward each other to hold the first workpiece 170 between the pair of arms 192 in the predetermined position and orientation.

[0066] Referring to Figure 8A, in the example illustrated, when in the closed position, the pair of arms 192 define a groove 194 between the pair of arms 192. Each groove 194 receives a respective first workpiece 170 to facilitate consistent positioning and orientation of the first workpiece 170 at the stop position. In the example illustrated, each groove 194 extends vertically through the pair of arms 192 for orienting the first axis 178 vertically. In the example illustrated, the pair of arms 192 include respective inner surfaces directed toward each other, and the grooves 194 are formed in the inner surface of one of the arms 192.

[0067] An example method of processing workpieces at the threading station 300 will now be described with reference to Figures 6 to 12. In the example illustrated, the control systems 120, 220 can be configured to electronically synchronize operation of the carriers 152, indexing device 154, robot 310, and workpiece alignment mechanism 190 to carry out the methods described herein for threading together the first and second workpieces 170, 172.

[0068] Referring to Figure 5, in the example illustrated, the pair of second workpieces 172 are loaded onto respective retainers 156 of the indexing device 154 at the loading position, and the rotary table of the indexing device 154 is rotated to advance the retainers 156 and second workpieces 172 to the unloading position.

[0069] Referring to Figure 6, in the example illustrated, the end effectors 312 of the robot 310 are moved to the pick-up position adjacent the unloading position to unload the second workpieces 172 from the indexing device 154. When in the pickup position, the pair of end effectors 312 are operated to simultaneously engage (e.g. grip) the pair of second workpieces 172 at the unloading position. In some examples, as the end effectors 312 operate to pick up and move the second workpieces 172 from the indexing device 154, the carrier 152 can be simultaneously advanced along the transport track 150 toward the stop position.

[0070] Referring to Figures 7 and 7A, in the example illustrated, while the end effectors 312 are in engagement with (e.g. gripping) respective second workpieces172, the end effectors 312 lift the second workpieces 172 off respective retainers 156 and are moved away from the pick-up position toward the threading position adjacent the track 150. During movement toward the threading position, the end effectors 312 can rotate the second workpieces 172 about respective second axes 180 to align the thread start of the second threading 176 with the expected angular position of the thread start of the first workpiece 170. In the illustrated example, during movement of the end effectors 312 toward the threading position, the carrier 152 is being advanced along the transport track 150 toward the stop position.

[0071] Referring to Figures 8 and 8A, in the example illustrated, the end effectors 312 are moved into the threading position, and the carrier 152 is advanced to the stop position. When the carrier 152 arrives at the stop position, each first workpiece 170 is held between the pair of arms 192 of the workpiece alignment mechanism 190 to maintain the first axis 178 at the predetermined position and orientation for coaxial alignment with the second axis 180 of the second workpiece 172 (when at the threading position). In the example illustrated, as the carrier 152 moves toward the stop position, movement of the pair of arms 192 from the open position toward the closed position is initiated. In the example illustrated, movement of the pair of arms 192 from the open position toward the closed position is initiated during deceleration of the carrier 152 toward the stop position, to synchronize arrival of the carrier 152 at the stop position with movement of the arms 192 to the closed position. When the arms 192 are closed with the carrier 152 at the stop position, each first workpiece 170 is received in a respective groove 194 formed between the pair of arms 192 in the closed position.

[0072] When the end effectors 312 holding the second workpieces 172 are in the threading position and the carrier 152 is at the stop position with the first workpieces 170 held by the workpiece alignment mechanism 190, the first and second axes 178, 180 of respective first and second workpieces 170, 172 are in coaxial alignment. In the example illustrated, the first axis 178 and the second axis 180 are oriented vertically when in coaxial alignment.

[0073] In the example illustrated, when the first and second axes 178, 180 are in coaxial alignment, the end effectors 312 are operated to thread together the first and second threading 174, 176 to assemble the first and second workpieces 170, 172. In the example illustrated, the end effectors 312 rotate the second workpiece 172 relative to the stationary first workpiece 170 and advance the second workpiece 172 vertically relative to the first workpiece 170 to thread together the first threading 174 and second threading 176 for assembly of the workpiece assembly 170a in the carrier 152. In the example illustrated, the end effector 312 rotates the second workpiece 172 about the second axis 180 relative to the first workpiece 170 at a rotation rate and advances the second workpiece 172 along the first axis 178 relative to the first workpiece 170 at a translation rate equal to a thread lead of the first threading 174 multiplied by the rotation rate to facilitate the threading operation.

[0074] In the example illustrated, the thread start of each first workpiece 170 is above the pair of arms 192 when closed, to facilitate engagement by the second workpiece 172 from above while the pair of arms 192 stabilize and align the upper portion of the first workpiece 170. In the example illustrated, after initial thread engagement between the first and second threading 174, 176, the pair of arms 192 are moved from the closed position back to the open position to accommodate the end effectors 312 moving further downwardly between the pair of arms 192 to rotate and further advance the second workpiece 172 relative to the first workpiece 170 for the threading operation. In some examples, the pair of arms 192 are moved from the closed position to the open position during threading (rotation and advancement) of the second workpieces 172 onto the first workpieces 170 by the end effectors 312.

[0075] Referring to Figures 11 and 12, in the example illustrated, after the first and second workpieces 170, 172 are assembled in the threading operation, the end effectors 312 are operable to release the second workpieces 172 move away from the carriers 152 back toward the pick-up position in electronic synchronization with advancement of the carriers 152 along the transport track 150 away from thestop position to prepare for another threading cycle with another set of first and second workpieces 170, 172. The threading process can be repeated continuously with subsequent first and second workpieces 170, 172 in a continuous mass production process.

Claims

CLAIMS1. A method of threading workpieces in an automated mass production process, comprising: a) advancing a carrier along a transport track to a stop position, the carrier holding at least one first workpiece, each first workpiece having first threading extending about a first axis; b) advancing at least one second workpiece to an unloading position spaced apart from the transport track, each second workpiece having second threading extending about a second axis, the second threading complementary to the first threading for forming a threaded connection between the first and second workpieces; c) operating at least one end effector to move the second workpiece from the unloading position toward the stop position to bring the second axis of the second workpiece into coaxial alignment with the first axis of a respective first workpiece at the stop position; and d) when the first and second axes are in coaxial alignment, operating the end effector to thread the first and second threading together through rotation and advancement of the second workpiece relative to the first workpiece for assembling the first and second workpieces in the carrier.

2. The method of claim 1 , wherein (c) includes operating a gripper of the end effector to grip the second workpiece, and (d) includes rotating the gripper about the second axis and advancing the gripper along the first axis while gripping the second workpiece.

3. The method of any one of claims 1 to 2, wherein the first and second axes are oriented vertically during (d).

4. The method of any one of claims 1 to 3, wherein each first workpiece projects upwardly from the carrier along the first axis, and the method furtherincludes holding each first workpiece at the stop position between a pair of arms of a workpiece alignment mechanism to maintain the first axis at a predetermined position and orientation for coaxial alignment with the second axis.

5. The method of claim 4, wherein the method includes moving the pair of arms relative to each other from an open position, in which the pair of arms are spaced apart from each other for receiving each first workpiece at the stop position between the pair of arms, to a closed position in which the pair of arms are moved toward each other relative to the open position to hold the first workpiece therebetween.

6. The method of claim 5, wherein the first workpiece is received in a respective groove formed between the pair of arms in the closed position.

7. The method of any one of claims 5 to 6, wherein movement of the pair of arms from the open position toward the closed position is initiated during deceleration of the carrier toward the stop position.

8. The method of any one of claims 5 to 7, further comprising, after initial thread engagement between the first and second threading during (d), moving the pair of arms from the closed position toward the open position to accommodate movement of the end effector downwardly between the pair of arms for further advancement of the second workpiece relative to the first workpiece during (d).

9. The method of any one of claims 1 to 8, further comprising, during movement of the second workpiece toward the stop position in (c), operating the end effector to rotate the second workpiece about the second axis for aligning a thread start of the second threaded portion with that of the first threaded portion.

10. The method of any one of claims 1 to 9, wherein each second workpiece is loaded onto a respective retainer of an indexing device prior to (c), and (b) includes advancing the retainer toward the unloading position.

11. The method of any one of claims 1 to 10, further comprising, after (d), (e) operating the end effector to release the second workpiece and advancing the carrier away from the stop position, and repeating (a) to (e) for threading together subsequent first and second workpieces in a continuous automated mass production process.

12. The method of any one of claims 1 to 11 , wherein the at least one end effector comprises a plurality of end effectors for picking up a plurality of respective second workpieces from the unloading position and threading the plurality of respective second workpieces onto a plurality of respective first workpieces at the stop position.

13. An automated mass production system for threading workpieces, comprising: a) a track including a plurality of carriers, each carrier holding at least one first workpiece and advanceable to a stop position along the track, each first workpiece having first threading extending about a first axis; b) an indexing device having a plurality of retainers, each retainer advanceable from a loading position for receiving a respective second workpiece to an unloading position spaced apart from the loading position for unloading of the second workpiece from the retainer, each second workpiece having second threading extending about a second axis, the second threading complementary to the first threading for forming a threaded connection between the first and second workpieces; and c) a pick-and-place robot having at least one end effector movable between a pick-up position adjacent the unloading position for pick-up of the second workpiece from the indexing device, and a threading position adjacent thestop position for coaxial alignment of the second axis of the second workpiece picked up by the end effector with the first axis of the first workpiece at the stop position, and when in the threading position, the end effector is operable to rotate the second workpiece about the second axis while advancing the second workpiece along the first axis to thread together the first and second threading for assembling the first and second workpieces in the carrier.

14. The system of clam 13, further comprising: (d) a workpiece alignment mechanism adjacent the stop position and operable to hold the first workpiece at the stop position at a predetermined position and orientation to facilitate the coaxial alignment of the first axis with the second axis.

15. The system of claim 14, wherein the alignment mechanism includes a pair of arms movable transversely relative to the track between an open position in which the arms are spaced apart from each other for receiving the first workpiece arriving at the stop position between the pair of arms, and a closed position in which the pair of arms are moved toward each other to hold the first workpiece between the pair of arms.

16. The system of claim 15, wherein when in the closed position, the pair of arms define at least one groove between the pair of arms, each groove for receiving a respective first workpiece at the stop position.

17. The system of claim 16, wherein each groove extends vertically through the pair of arms for orienting the first axis vertically.

18. The system of any one of claims 13 to 17, wherein the end effector includes a gripper operable to grip the second workpiece at the unloading position for pick up and movement of the second workpiece to the threading position, and to rotate about and translate along the second axis while gripping the second workpiece at the threading position.

19. The system of any one of claims 13 to 18, wherein the indexing device comprises a rotary table.

20. The system of any one of claims 13 to 19, further comprising a control system for synchronizing operation of the carriers, indexing device, and pick-and- place robot to perform the method of any one of claims 1 to 12.

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