Automated workpiece insertion assembly

Abstract

A workpiece dispensing apparatus comprising: a hopper for receiving a plurality of workpieces; a guiding mechanism for guiding the plurality of workpieces from the hopper to an exit port, wherein the guiding mechanism comprises a first track and a second track separated from each other by a first distance and defining a channel therebetween, the channel having a shape to maintain the plurality of workpieces in a first orientation; means for rotating the hopper such that the plurality of workpieces and introduced into the channel; and means for vibrating the guiding mechanism to cause the plurality of workpieces to move along the guiding mechanism towards the exit port.

Description

AUTOMATED WORKPIECE INSERTION ASSEMBLYFIELD

[0001] The present disclosure relates to automated assembling systems, more particularly it pertains to dispensing and placing workpieces in an orientation suitable for a desired application.BACKGROUND

[0002] The manufacturing industry relies on precise part orientation for automated assembly. Such parts may include clips, nuts, bolts, screws, nails, dowels, and other fasteners. One common approach for part orientation and sorting involves passive feeders, such as vibratory bowl feeders, in which the parts are vibrated in a bowl with a helical track and fdtered into a specific orientation. Some disadvantages of using bowl feeders are that they are often large in scale and substantially heavy, and are also prone to jams which can pause production and can therefore have economic impacts. In addition, should the part type or part geometry change, the bowl feeders have to be redesigned and replaced, which is a costly and time-intensive process.

[0003] Several other approaches have been proposed for sorting parts, such as, blow-feeders which transfer the individual parts, in single file, from one location to another location using compressed air in a profiled tube, often fed by a bowl feeder.

[0004] In another approach, a conventional 6-axis robot is used to retrieve parts from the flat conveying surface utilizing vision guidance. However, such systems require a sturdy steel structure, and are difficult to maintain, time consuming to program and carry a high upfront hardware cost. Integration complexity also attributes to higher upfront costs. In addition, these systems have lower through-put rates, increasing time to return on investment and a larger footprint, increasing floor space requirements. Other approaches use bowl feeders in conjunction with 6-axis robots.

[0005] In these approaches, there is no redundancy built-in to mitigate against common pitfalls such as jams or equipment failures, in order to ensure that throughput, productivity and profitability are maintained.SUMMARY

[0006] In one aspect, a workpiece dispensing apparatus comprising:a hopper for receiving a plurality of workpieces;a guiding mechanism for guiding the plurality of workpieces from the hopper to an exit port, wherein the guiding mechanism comprises a first track and a second track separated from each other by a first distance and defining a channel therebetween, the channel having a shape to maintain the plurality of workpieces in a first orientation;means for introducing the plurality of workpieces into the channel; means for causing the plurality of workpieces to move along the guiding mechanism towards the exit port.

[0007] In another aspect, an automated workpiece insertion assembly comprising:a least one workpiece dispensing apparatus comprising:a hopper for receiving a plurality of workpieces; a guiding mechanism for guiding the plurality of workpieces from the hopper to an exit port, wherein the guiding mechanism comprises a first track and a second track separated from each other by a first distance and defining a channel therebetween, the channel having a shape to maintain the plurality of workpieces in a first orientation;means for introducing the plurality of workpieces into the channel;means for causing the plurality of workpieces to move along the guiding mechanism towards the exit port; and a workpiece insertion tool comprising a magazine for receiving the plurality of workpieces from the exit port, wherein the workpiece insertion tool is configured to drive the plurality of workpieces into a component.

[0008] In another aspect, a workpiece dispensing apparatus comprising:a rotatable hopper configured to receive a plurality of workpieces; a guiding assembly comprising a horizontal portion and a vertical portion,wherein the horizontal portion and the vertical portion comprise a first rail and a second rail defining a channel shaped and sized to support the plurality of workpieces in a first orientation, the first rail and a second rail being separated by a first distance;a vibrator operatively coupled to at least one of the rails and configured to advance the plurality of workpieces along the channel;a vertical portion coupled to the guiding assembly, wherein the vertical portion receives the plurality of workpieces and maintains the plurality of workpieces in a second orientation;a sensor positioned along the vertical portion to detect workpiece flow and a jam condition; anda separation actuator responsive to the jam condition, wherein the separation actuator is configured to translate the first rail away from the second rail from the first distance to a second distance, such that the second distance is greater than the first distance, to clear the jam.

[0009] In another aspect, a workpiece dispensing apparatus comprising:a rotatable hopper having a plurality of workpieces;a guiding assembly for receiving the plurality of workpieces, wherein the guiding assembly comprises a horizontal portion within the hopper and a vertical portion, and wherein the guiding assembly comprises a first rail and a second rail defining a channel shaped and sized to support the plurality of workpieces in a first orientation;a sensor configured to detect the plurality of workpieces passing in the vertical portion onto a vertical stack and configured to detect when the vertical stack is full of the plurality of workpieces; and whereby when a workpiece does not pass by in a predefined amount of time then an anti -jam mode is triggered.

[0010] In another aspect, a magazine assembly having a first magazine portion and a second magazine portion, the magazine assembly comprising:a vertical chute defined within the first magazine portion and a secondmagazine portion, the vertical portion configured to receive workpieces in a second orientation from a workpiece dispensing apparatus;a gate to retain a stack of the workpieces;a rotary plunger having a workpiece-engaging tip and configured to rotate and translate to withdraw a lowermost workpiece from the stack and transfer the workpieces into a spring-loaded chamber that constrains the workpiece in a third orientation for pickup by an insertion tool;at least one sensor positioned along the vertical chute to detect workpiece level; anda separation actuator configured, responsive to a jam condition detected by the sensor, to translate the first magazine away from the second magazine from a spacing di to a spacing 2, whereby the spacing / is greater than spacing di to clear the jam condition.

[0011] In another aspect, a magazine assembly associated with a workpiece dispensing apparatus, the magazine assembly comprising:a first magazine portion and a second magazine portion; a vertical chute defined within the first magazine portion and a second magazine portion, the vertical portion configured to receive workpieces in a second orientation from a workpiece dispensing apparatus;a gate to retain a stack of the workpieces;a rotary plunger having a workpiece-engaging tip and configured to rotate and translate to withdraw a lowermost workpiece from the stack and transfer the workpieces into a spring-loaded chamber that constrains the workpiece in a third orientation for pickup by an insertion tool;at least one first sensor positioned along the vertical chute to detect a high level of the workpieces in the vertical chute;at least one second sensor positioned along the vertical chute to detect a low level of the workpieces in the vertical chute;at least one third sensor configured to detect the actuation of the rotary plunger to transfer the workpieces into the spring-loaded chamber, and when the rotary plunger does not meet full stroke for transferring the workpieces, a jam condition is detected by the at least one third sensor;a separation actuator configured, responsive to a jam conditiondetected by the sensor, to translate the first magazine away from the second magazine from a spacing di to a spacing d2, whereby the spacing d2 is greater than spacing di, thereby clearing the jam condition.

[0012] The assembly comprises multiple compact feeders for greater redundancy and reliability. In addition, the feeders that are not impacted by clip quality issues, and can work with a family of clips with little to no modifications. Furthermore, unlike robot-based systems and conventional bowl feeders, the assembly has a much smaller footprint / safe zone, and weighs substantially less. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figures la-c show various views of an automated workpiece insertion system, in one example.;

[0014] Figure 2a shows a workpiece dispensing apparatus;

[0015] Figure 2b shows a perspective view of a workpiece guiding mechanism;

[0016] Figure 2c shows a top view of a workpiece guiding mechanism with tracks in a first position;

[0017] Figure 2d shows a top view of a workpiece guiding mechanism with tracks in a second position;

[0018] Figure 3a shows a workpiece, in one example;

[0019] Figure 3b shows the workpiece applied to a component, in one example;

[0020] Figure 4a shows a magazine for retaining workpieces, in one example;

[0021] Figures 4b and 4c show a portion of the magazine of Figure 4a;

[0022] Figure 4d shows a perspective view of the clip tool;

[0023] Figure 4e shows a side view of the clip tool;

[0024] Figure 4f shows a top view of the clip tool;

[0025] Figure 4g shows an enlarged portion of the clip tool;

[0026] Figure 4h shows a cross-sectional view of the clip tool taken along line F-F in Figure 4g; and

[0027] Figure 5 shows a flow chart with example steps for operating the automated workpiece insertion assembly.DETAILED DESCRIPTION

[0028] Various embodiments are discussed in detail below. While specific implementations are discussed, it should be understood that this is done forillustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. Like reference numerals are used to designate like parts in the accompanying drawings.

[0029] The detailed description provided below in connection with the appended drawings is intended as a description of the present examples and is not intended to represent the only forms in which the present example may be constructed or used. However, the same or equivalent functions and sequences may be accomplished by different examples.

[0030] Looking at Figures la-c, there is shown an automated workpiece insertion system or assembly 10, in one example. The automated workpiece insertion assembly 10 comprises one or more workpiece dispensing apparatuses 12 which store and dispense a plurality of workpieces 14, a workpiece insertion tool 16 which receives workpieces 14 from the workpiece dispensing apparatus 12. The workpiece dispensing apparatus 12 and the workpiece insertion tool 16 are mounted on a X-Y gantry stage 18, such that the workpiece insertion tool 16 is moveable in an X-Y plane and operable to drive the workpieces 14 into a component 20 in a desired application. The insertion tool 16 also includes a combination vertical (Z) and rotation (R) axis 80 to maneuver the workpiece 14.

[0031] In more detail, as shown in Figure 2a the workpiece dispensing apparatus 12 comprises a feeder hopper 22 for receiving a plurality of workpieces 14; a guiding assembly or mechanism 24 for transporting the plurality of workpieces 14 from the hopper 22 towards an exit port that interfaces with the workpiece insertion tool 16. Figure 2b shows a perspective view of a workpiece guiding mechanism 24. Looking at Figure 2c, the guiding mechanism 24 comprises a first track 26 and a second track 28 separated from each other by a first distance (di) and defining a channel 30 therebetween, in a first or closed position of the guiding mechanism 24. Figure 2d shows a top view of a workpiece guiding mechanism 24 with first track 26 and second track 28 separated from each other by a first distance (d.2) and defining a channel 30 therebetween, in a second or closed position of the guiding mechanism 24.

[0032] In one example, the workpiece 14 is a fastener, such as a clip, which may be used to replace screws when assembling components 20. In one example, the clips 14 provide a secure connection that is hidden resulting in improved aesthetics, eliminating an ingress point, reducing a failure point where a steel fastener can rust out, lightweighting and ease of assembly to name a few. For example, clip 14 may be used in the automotive industry for holding plastic trim panels onto the interior and exterior of vehicles, and may also be used in other industries such as appliance assembly. Generally, the clips 14 are molded separately and clipped into the component 20 for any number of reasons, such as difficulty of molding complex geometry, differing material properties, and ability to replace. As such, the clips 14 are an attractive fastening method for cars, and may be combined with adhesive tape, to provide the alignment and temporary holding power while the adhesive can provide a more permanent bond. The workpiece dispensing apparatus 12 comprises means for rotating the hopper 22, such as a motor 93, such that as the hopper 22 rotates the clips 14 and tumble, a paddle 23 lifts the clips 14 up and drops onto the channel 30.

[0033] In one example, the hopper 22 may comprise one or more brushes 56 and two paddles 23 spaced evenly and alternating (e.g. two brushes and two paddles at 90 degree increments i.e. paddle, brush, paddle brush) around the circumference of the hopper 22. As the hopper 22 rotates a paddle 23 lifts the workpieces 14 up, when it rotates up over the channel 30 they are positioned on such an angle to cause the workpieces 14 to slide off the paddle 23 at the right time. The angle of the paddle 23 is adjustable with slots to allow for adjustment of the timing of the drop, for example the paddles 23 may be positioned at 42 degrees to scoop the clips 14. After the paddle 23 dumps the clips 14, the hopper 22 continues rotating and aturn later the brush 56 wipes past the channel 30, the brush 56 positioned at a -15 degree angle, biased backwards to create a brushing action to dislodge any workpieces 14 that sit above the edge of the channel 30 pushing them back into the hopper 22, or causing the clips 14 to orientate properly in the channel 22. The brushes 56 are also adjustable to change the amount of contact and level of force applied to dislodge mis-orientated clips 14.

[0034] The channel 30 may be shaped to match the shape of the clip 14, and therefore the channel 30 may comprise a plurality of shapes to complement the plurality of shapes of the clips 14. In one example, the channel 30 is V-shaped, thereby complementing the V-shaped clip 14, as can be seen in Figure 2b. Looking at Figures 3a and 3b, the clip 14 is generally V-shaped, and comprises an intermediate portion 40 in the form of a clamp having two wings 42, 44 and portions 46, 48 with flanges 50, 52, respectively. The intermediate portion 40 is suitable for receiving and / or co-operating with at least a projecting portion 54 of the component 20. As such, the intermediate portion 40 and two wings 42, 44 are resiliently biased for snap-fitting on the projecting portion 54 of the component 20, as shown in Figure 3b. In one example, the clip 14 comprises opposing 20-degree angles forming a total 40-degree V-shape; and a radius e.g. about 6mm, meets the top of the angled channel 30 to provide adequate clearance for removal of mis-orientated clips 14. The rear of the channel 30 has a clearance angled cut, also forming a 40-degree angle to allow clips 14 to fall through that are placed sideways. As such, the V-shaped clip 14 may be received in the V-shaped channel 30 such that the two wings 42, 44 abut the V-shaped channel 30 thereby position the clip 14 in a desired orientation for transport along the guiding mechanism 24. Any misoriented clips 14 fall through the V-shaped channel 30 and back into the hopper 22.

[0035] As stated above, properly oriented clips 14 will rest within the V-shaped channel 30 with the two wings 42, 44 abutting the V-shaped channel 30. One or more brushes 56 are positioned adjacent to the guiding mechanism 24 to remove misoriented clips 14 resting on properly oriented clips 14 within the V-shaped channel 30, or misoriented clips 14 lying horizontally on the tracks 26, 28. In one example, the brushes 56 comprise bristles made from nylon, metal or other non-metallic materials, chosen to maximize wear resistance. The tracks 26, 28 form a horizontal sloped portion 60 disposed within the hopper 22 and the vertical portion 62 disposed outside the hopper 22. The tracks 26, 28 may be manufactured from several materials depending on the material of the clip 14, such as plastic or metal e.g. aluminum or steel. There is provided a means for causing the clips 14 to move in single fde along the V-shaped channel 30 of the horizontal sloped portion 60 andfall into the vertical channel 65 at one end of the vertical portion 62. In one example, a vibrating means, such as a vibrator 67, may be used to move the clips 14 along. In one example, the vibrator 67 is actuated at a first harmonic frequency to move clips in a forward direction toward the vertical portion 62, and a second harmonic frequency to move clips backward into the hopper 22. In one example, the first and second harmonic frequencies are in the range of 15-120Hz. In one example, the first harmonic frequencies for forward motion are between 18 and 60Hz depending on material of the tracks 26, 28 and the mounting rigidity. While in another example, a belt means caused to move backwards, and forwards may be used. In another example, an air jet or other means may be used. At the other end of the vertical portion 62 is an exit port with a solenoid-operated gate 68, and the clips are received and stacked in the vertical channel on top of the gate 68. As such the vertical portion 62 maintains the plurality of clips 14 in a second orientation, e.g. sideways, such that the clips 14 pile on top of each other with the two wings 42, 44, portions 46, 48 with flanges 50, 52 of one clip 14 abutting the two wings 42, 44, portions 46, 48 with flanges 50, 52 of another clip 14, in a stacked manner. When a predetermined number of clips 14 are stacked within the vertical portion 62, the gate 68 is actuable to open to release the clips 14 into a magazine 70 of the insertion tool or clip head 16. In one example, the gate 68 comprises a short linear movement or pivoting linkage actuated by any one of an electric motor, pneumatic actuator, a solenoid, or an electromagnet.

[0036] In one example, the magazine 70 holds a sufficient number of clips 14 in a vertical chute 71 for at least one full part cycle. In one example, the clip head 16 is lightweight, capable of highspeed motion in the X-Y plane, holds approximately 30 clips, and has less reload cycles. As can be seen in Figures 4a-4c, the magazine 70 comprises a rotary plunger 72 that is actuatable to take the bottom clip 74 from the stack and out of the magazine 70, and push the clip 14 into a spring-loaded chamber 76, and then reverses the rotary plunger 72 back out. In one example, the rotary plunger 72 is about 100mm in diameter and actuates through a rotation path of about 102 degrees to move the clips 14. In one example, the rotary plunger 72 is pneumatically actuated, in another it is electrically actuated with a motor 92, such as a Nema 17 stepper motor producing 64oz-in of torque. The rotary plunger 72 flipsthe clip 14 into a vertical orientation, and a spring mechanism 78 holds the clip 14 until a clip tool 84 can grab the clip 14. In one example, the spring chamber 76 is configured to accept clips 14 in vertical orientation and held with pressure applied by spring mechanism 78. The spring chamber 76 is configured to allow the clip tool 84 to pass through while maintaining a narrow passage to guide the clip 14 into the spring mechanism 78. In another example, spring door 79 is configured to guide workpiece 14 into spring chamber 76 and return to normal position so insertion tool 84 can pass through unobstructed.

[0037] The guiding mechanism 24 comprises one or more sensors for detecting the clips 14 exiting the channel 30 into vertical portion 62. As the hopper 22 rotates and the vibrator 67 operates, when the one or more sensors fail to detect the clips 14 entering the vertical portion 62, or magazine 70, in a predefined period, that may be indicative of a jammed clip or clips, or a jamming event. Accordingly, if a jamming event is suspected or evident in the track system 24, then the workpiece dispensing apparatus 12 initiates an unjamming sequence. In one example, the unjamming sequence comprises enabling the vibrator 67 at 36Hz to cause the clips to move backward in the tracks 26, 28 which can cause the jams located in the channel 30 to clear. The sequence then begins again with an attempted refill of vertical portion 62, if unsuccessful a second time, the workpiece dispensing apparatus 12 initiates the second stage un-jamming sequence, first consisting of a reverse vibration at 36Hz for 3 seconds, then a guide rail actuator is caused to automatically separate the first track 26 and the second track 28 from each other by a second distance db into an open position of guiding mechanism 24, whereby the second distance ( ) is greater than the first distance (dj), thereby dislodging the stuck clips 14 to clear the channel 30, or vertical portion 62, thereby clearing any jams automatically and allowing the machine to continue operation. The magazine 70 also comprises one or more sensors 82, 85 for detecting the clips 14 within the magazine 70. In one example, d2 is dimensioned to permit the clearance of jams for a differently sized or shaped clips 14. In one example, spacing d2 of the magazine 70 is dimensioned to allow for clips of varying sizes to exit by way of gravity downwards, and may range from 0mm to 30mm. In one example, d2 is approximately 30mm. In one example, spacing d2 of the guiding mechanism 24 tracks 26, 28 of the horizontal portion 60 ranges from 7mmto 37m. Furthermore, spacing di of the guiding mechanism 24 tracks 26, 28 of the horizontal portion 60 may be adjusted depending on clip size to ensure mis-oriented clips 14 can fall through the channel 30. In one example, di is 7mm.

[0038] Figure 5 shows a flow chart 100 with example steps for operating the automated workpiece insertion assembly 10, in one example. In step 102, the hopper 22 is loaded with a bulk bag of clips 14. In one example, the clips 14 are sufficient for applications or tasks lasting at least 4 hours, however, the hopper 22 may comprise various dimensions depending on the task at hand. In addition, the assembly 10 comprises multiple hoppers 22 associated with redundant workpiece dispensing apparatuses 12, which serve to reduce downtimes for replenishing the hopper 22, or clearing jams, thereby increasing the production throughput.

[0039] In step 102, the hopper 22 is caused to rotate, and a paddle 23 lifts the clips 14 up and drops the clips 14 on the channel 30 of the guiding mechanism 24. As stated above, the clips 14 that fall and land in the channel 30 with the arms 42, 24 abutting the inside surface of the channel 30 are considered to be properly oriented, otherwise if the clips 14 are in the wrong orientation then these clips 14 are not retained within the channel 30 and fall through the channel 30 back into the hopper 22. Any clips 14 sitting on top of other clips 14 are pushed off by a removal means, such as brushes 56, wipers or air jets, or other means, installed within the hopper 22, or associated therewith.

[0040] In step 104, a vibrator 67 such as a voice coil actuator, associated with the first track 26 and / or the second track 28 is actuated at a harmonic frequency and causes the clips 14 to gently move down the first track 26 and the second track 28 of the sloped horizontal portion 60 along the V-shaped channel 30 and fall down the vertical channel 65 of the vertical portion 62 of the guiding mechanism 24.

[0041] In step, 106, the vertical channel 65 orients the clips 14 sideways such that the clips 14 pile on top of each other with the two wings 42, 44, portions 46, 48 with flanges 50, 52 of one clip 14 abutting the two wings 42, 44, portions 46, 48 with flanges 50, 52 of another clip 14, in a stacked manner, and rest on a gate 68 adjacent an exit port of the vertical channel 65.

[0042] In step 108, a high clip level sensor 64 associated with the vertical portion 62 detects the clips 14 therein, and the clips 14 are stacked within thevertical portion 62 until the top clip 14 breaks a high clip level sensor 64 beam triggering the hopper 22 to stop rotating, and the vibrator 67 to stop vibrating, thereby interrupting the supply of clips 14 into the vertical portion 62, otherwise the hopper 22 keeps rotating and the vibrator 67 continues to vibrate for continued transport and stacking of the clips 14 in the vertical portion 62.

[0043] In step 110, the gate 68 is actuated to open to release the clips 14 into a magazine 70 of the insertion tool 16. In one example, the magazine 70 holds a sufficient number of clips 14 for at least one full part cycle.

[0044] In step 112, the rotary plunger 72 positioned within the magazine 70 is actuated to remove the bottom clip 24 from the stack and out of the magazine 70, and push the clip 14 into a spring-loaded chamber 76. In another example, this may be a magnetic chamber, a crowder or an actuated gripper. The rotary plunger 72 flips the clip 14 into a vertical orientation; and a spring mechanism 78 holds the clip 14 until a clip tool 84 takes the clip 14 in preparation for application by the clip head 16.

[0045] Next in step 114, the combination vertical (Z) and rotation (R) axis 80 extends by way of an electric motor through the spring-loaded chamber 76 where the clip is forced into the insertion tool 16. Without stopping, the combination vertical (Z) and rotation (R) axis 80 continues downward, adjusts to the proper angle mid movement and the combination vertical (Z) and rotation (R) axis 80 completes the final push to snap the clip 14 into the subject component 20. The combination vertical (Z) and rotation (R) axis 80 retracts back through the chamber 76.

[0046] The magazine 70 comprises a low clip level sensor 82 which detects and reports the quantity of clips 14 in the magazine 70. The low clip level sensor 82 is configured to detect the minimum number of clips 14 for one full cycle, at the end of a previous cycle, the low clip level sensor 82 is checked to confirm there are enough clips 14 to complete the next cycle, if there is not, the machine 10 initiates a refill sequence. If the low clip level sensor 82 detects that the quantity of clips 14 is below a predetermined threshold, the X-Y gantry stage 18 moves the clip head 16 to the workpiece dispensing apparatus 12 to pick up a new load of clips 14, if the low clip level sensor 82 does not detect a low level of clips 14 within the magazine 70, then the clip head 16 returns back to a waiting position or clip 1 position. The cyclerepeats. As can be seen in Figure 1, the automated workpiece insertion assembly 10 comprises a plurality of workpiece dispensing apparatuses 12 for built-in redundancy to mitigate against equipment failures or jams, to ensure uninterrupted or continuous runs. Each workpiece dispensing apparatus 12 operates a sequence independently of machine function, ensuring to refdl and unjam as required to be ready as soon as possible. When a workpiece dispensing apparatus 12 detects that the vertical portion 62 is full it shuts off all motions and sends a ready to dispense signal to the automated workpiece insertion assembly 10. When automated workpiece insertion assembly 10 determines it requires a refdl it will travel to the closest ready to dispense workpiece dispensing apparatus 12 and position the magazine 70 into alignment with vertical portion 62 at a predefined X Y gantry position. The automated workpiece insertion assembly 10 sends the workpiece dispensing apparatus 12 a ready to fill command, the workpiece dispensing apparatus 12 initiates a dispense sequence. The sequence first begins with a 10mm downward actuation 89 of vertical portion 62, followed by the opening actuation of gate 68. Sensors 64 and 82 verily the clips have left vertical portion 62 and entered magazine 70. The workpiece dispensing apparatus 12 returns the vertical portion 62 upwards and the refill is complete. As such, the clip head 16 can cycle through the plurality of workpiece dispensing apparatuses 12 picking up clips without having to wait. If sensor 82 in head 16 does not sense the incumbent clips, the control system initiates a jam sequence.

[0047] In another implementation, the clips 14 may be pushed into the component 20 by a spring loaded, compliant, vacuum, pneumatic grippers, bellow gripper, profiled block, manual tool, star wheel and a blowfeed tool.

[0048] In one example, the assembly 10 comprises a machine, controller or computing system 90 configured to control or operate the various components of the automated workpiece insertion assembly 10, such as the motors, sensors 64, 82, 85, gate 68, vibrator 67, rotary plunger 72, gantry stage 18, clip head 16. The machine or computing system 90 comprises processing circuitry such as one or more processors, at least one memory device such as a memory, and an input / output (I / O) module, which are in communication with each other via centralized circuit system. In an embodiment, the memory is capable of storing machine executableinstructions, and data. A database for storing data may also be coupled to the computing system 90. Further, the processor is capable of executing the instructions in the memory to implement aspects of processes described herein. For example, the processor may be embodied as an executor of software instructions, wherein the software instructions may specifically configure the processor to perform algorithms and / or operations described herein when the software instructions are executed. Alternatively, the processor may be configured to execute hard-coded functionality.

[0049] Examples of the I / O module include, but are not limited to, an input interface and / or an output interface. Some examples of the input interface may include, but are not limited to, a keyboard, a mouse, a joystick, a keypad, a touch screen. Some examples of the output interface may include, but are not limited to, a microphone, a speaker, a ringer, a graphical user interface. In an example embodiment, the processor may include I / O circuitry configured to control at least some functions of one or more elements of I / O module, such as, for example, a speaker, a microphone, a display, and / or the like. The processor and / or the I / O circuitry may be configured to control one or more functions of the one or more elements of the I / O module through computer program instructions, for example, software and / or firmware, stored on a memory, for example, the memory, and / or the like, accessible to the processor.

[0050] A communication interface associated with the I / O module enables computing system 90 to communicate with other entities over various types of wired, wireless or combinations of wired and wireless networks, such as for example, the Internet. The communication interface facilitates communication between the computing system 90 and I / O peripherals. In at least one example embodiment, the communication interface includes a transceiver circuitry configured to enable transmission and reception of data signals over the various types of communication networks. In some embodiments, the communication interface may include appropriate data compression and encoding mechanisms for securely transmitting and receiving data over the communication networks.

[0051] The centralized circuit system may be various devices configured to, among other things, provide or enable communication between the components of computing system 90. In certain embodiments, the centralized circuit system may bea central printed circuit board (PCB) such as a motherboard, a main board, a system board, or a logic board. The centralized circuit system may also, or alternatively, include other printed circuit assemblies (PCAs), communication channel media or bus.

[0052] A plurality of user computing devices and data sources may be coupled to computing system 90 with a communication network.

[0053] In more detail, the processor may be embodied as a multi-core processor, a single core processor, or a combination of one or more multi-core processors and one or more single core processors. For example, the processor may be embodied as one or more of various processing devices, such as a coprocessor, a microprocessor, a controller, a digital signal processor (DSP), a processing circuitry with or without an accompanying DSP, or various other processing devices including integrated circuits such as, for example, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a microcontroller unit (MCU), a hardware accelerator, a special-purpose computer chip, Application-Specific Standard Products (ASSPs), System-on-a-chip systems (SOCs), Complex Programmable Logic Devices (CPLDs), Programmable Logic Controllers (PLC), Graphics Processing Units (GPUs), and the like. For example, some or all of the device functionality or method sequences may be performed by one or more hardware logic components.

[0054] The memory may be embodied as one or more volatile memory devices, one or more non-volatile memory devices, and / or a combination of one or more volatile memory devices and non-volatile memory devices. The term “machine readable medium” can include any medium that is capable of storing, encoding, or carrying instructions for execution by the machine 90 and that cause the machine 90 to perform any one or more of the techniques of the present disclosure, or that is capable of storing, encoding or carrying data structures used by or associated with such instructions. Nonlimiting machine-readable medium examples can include solid-state memories, and optical and magnetic media. Specific examples of machine-readable media can include: non-volatile memory, such as semiconductor memory devices (e.g., Electrically Programmable Read-Only Memory (EPROM), Electrically Erasable Programmable Read-Only Memory (EEPROM)) and flashmemory devices; magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; Random Access Memory (RAM); Solid State Drives (SSD); and CD-ROM and DVD-ROM disks. In some examples, machine readable media can include non-transitory machine-readable media. In some examples, machine readable media can include machine readable media that is not a transitory propagating signal.

[0055] The communication interface enables computing system 90 to communicate with other entities over various types of wired, wireless or combinations of wired and wireless networks, such as for example, the Internet. In at least one example embodiment, the communication interface includes a transceiver circuitry configured to enable transmission and reception of data signals over the various types of communication networks. In some embodiments, communication interface may include appropriate data compression and encoding mechanisms for securely transmitting and receiving data over the communication networks. The communication interface facilitates communication between computing system 90 and I / O peripherals.

[0056] It is noted that various example embodiments as described herein may be implemented in a wide variety of devices, network configurations and applications.

[0057] Those of skill in the art will appreciate that other embodiments of the disclosure may be practiced in network computing environments with many types of computer system configurations, including personal computers (PCs), industrial PCs, desktop PCs), hand-held devices, multi-processor systems, microprocessorbased or programmable consumer electronics, network PCs, server computers, minicomputers, mainframe computers, and the like. Accordingly, system 90 may be coupled to these external devices via the communication, such that system 90 is controllable remotely. Embodiments may also be practiced in distributed computing environments where tasks are performed by local and remote processing devices that are linked (either by hardwired links, wireless links, or by a combination thereof) through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.

[0058] Examples, as described herein, can include, or can operate on, logic or a number of components, modules, or mechanisms (all referred to hereinafter as“modules”). Modules are tangible entities (e.g., hardware) capable of performing specified operations and is configured or arranged in a certain manner. In an example, circuits are arranged (e.g., internally or with respect to external entities such as other circuits) in a specified manner as a module. In an example, the whole or part of one or more computer systems (e.g., a standalone, client or server computer system) or one or more hardware processors are configured by firmware or software (e.g., instructions, an application portion, or an application) as a module that operates to perform specified operations. In an example, the software can reside on a non-transitory computer readable storage medium or other machine-readable medium. In an example, the software, when executed by the underlying hardware of the module, causes the hardware to perform the specified operations.

[0059] Accordingly, the term “module” is understood to encompass a tangible entity, be that an entity that is physically constructed, specifically configured (e.g., hardwired), or temporarily (e.g., transitorily) configured (e.g., programmed) to operate in a specified manner or to perform part or all of any operation described herein. Considering examples in which modules are temporarily configured, each of the modules need not be instantiated at any one moment in time. For example, where the modules comprise a general-purpose hardware processor configured using software, the general-purpose hardware processor is configured as respective different modules at different times. Software can accordingly configure a hardware processor, for example, to constitute a particular module at one instance of time and to constitute a different module at a different instance of time.

[0060] Examples, as described herein, can include, or can operate on, logic or a number of components, modules, or mechanisms. Modules are tangible entities (e.g., hardware) capable of performing specified operations and are configured or arranged in a certain manner. In an example, circuits are arranged (e.g., internally or with respect to external entities such as other circuits) in a specified manner as a module. In an example, the whole or part of one or more computer systems (e.g., a standalone, client, or server computer system) or one or more hardware processors are configured by firmware or software (e.g., instructions, an application portion, or an application) as a module that operates to perform specified operations. In an example, the software can reside on a machine-readable medium. In an example, thesoftware, when executed by the underlying hardware of the module, causes the hardware to perform the specified operations.

[0061] Various embodiments are implemented fully or partially in software and / or firmware. This software and / or firmware can take the form of instructions contained in or on a non-transitory computer-readable storage medium. Those instructions can then be read and executed by one or more processors to enable performance of the operations described herein. The instructions are in any suitable form, such as but not limited to source code, compiled code, interpreted code, executable code, static code, dynamic code, and the like. Such a computer-readable medium can include any tangible non-transitory medium for storing information in a form readable by one or more computers, such as but not limited to read only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory; etc.

[0062] Implementations of the subject matter and the functional operations described in this specification can be implemented in digital electronic circuitry, in tangibly embodied computer software or firmware, in computer hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Implementations of the subject matter described in this specification can be implemented as one or more computer programs, i.e., one or more modules of computer program instructions encoded on a tangible, non-transitory computer-storage medium for execution by, or to control the operation of, data processing apparatus. Alternatively, or in addition, the program instructions can be encoded on an artificially generated propagated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal that is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus. The computer-storage medium can be a machine-readable storage device, a machine-readable storage substrate, a random or serial access memory device, or a combination of one or more of them.

[0063] A computer program, which may also be referred to or described as a program, software, a software application, a module, a software module, a script, or code can be written in any form of programming language, including compiled or interpreted languages, or declarative or procedural languages, and it can be deployedin any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program may, but need not, correspond to a fde in a fde system. A program can be stored in a portion of a fde that holds other programs or data, e.g., one or more scripts stored in a markup language document, in a single fde dedicated to the program in question, or in multiple coordinated fdes, e.g., fdes that store one or more modules, sub-programs, or portions of code. A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network. While portions of the programs illustrated in the various figures are shown as individual modules that implement the various features and functionality through various objects, methods, or other processes, the programs may instead include a number of sub-modules, third-party services, components, libraries, and such, as appropriate. Conversely, the features and functionality of various components can be combined into single components, as appropriate.

[0064] The processes and logic flows described in this specification can be performed by one or more programmable computers executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, e.g., a CPU, a GPU, an FPGA, or an ASIC.

[0065] The preceding detailed description of exemplary embodiments of the invention makes reference to the accompanying drawings, which show the exemplary embodiment by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be realized and that logical and mechanical changes may be made. For example, the steps recited in any of the method or process claims may be executed in any order and are not limited to the order presented. Further, the present invention may be practiced using one or more servers, as necessary. Thus, the preceding detailed description is presented for purposes of illustration only and not of limitation, and the scope of the invention is defined by the preceding description, and with respect to the attached claims.

Claims

CLAIMS:

1. A workpiece dispensing apparatus comprising:a hopper for receiving a plurality of workpieces;a guiding mechanism for guiding the plurality of workpieces from the hopper to an exit port, wherein the guiding mechanism comprises a first track and a second track separated from each other by a first distance and defining a channel therebetween, the channel having a shape to maintain the plurality of workpieces in a first orientation;means for introducing the plurality of workpieces into the channel; andmeans for causing the plurality of workpieces to move along the guiding mechanism towards the exit port.

2. The workpiece dispensing apparatus of claim 1, wherein the plurality of workpieces comprise a complementary shape with the channel shape, such that the plurality of workpieces are maintained in the first orientation otherwise the plurality of workpieces fall through the channel.

3. The workpiece dispensing apparatus of claim 2, further comprising at least one brush positioned adjacent to the guiding mechanism to minimize the plurality of workpieces resting on the plurality of workpieces in the first orientation within the channel.

4. The workpiece dispensing apparatus of claim 3, wherein the guiding mechanism comprises a sloped portion disposed within the hopper and vertical portion disposed outside the hopper.

5. The workpiece dispensing apparatus of claim 4, wherein sloped portion maintains the plurality of workpieces in the first orientation portion and the vertical portion maintains the plurality of workpieces in a second orientation.

6. The workpiece dispensing apparatus of claim 5, wherein the plurality of workpieces are stacked in the second orientation within the channel of the vertical portion.

7. The workpiece dispensing apparatus of claim 6, wherein the vertical portion comprises the exit port, and wherein a gate is disposed at the exit port.

8. The workpiece dispensing apparatus of claim 7, wherein the plurality of workpieces are stacked on top of the gate, and the gate is actuable to open to release the plurality of workpieces.

9. The workpiece dispensing apparatus of claim 8, wherein the plurality of workpieces are released into a magazine configured to retain the plurality of workpieces in a stacked manner in the second orientation.

10. The workpiece dispensing apparatus of claim 5, wherein the guiding mechanism comprises at least one sensor for detecting the plurality of workpieces within the channel.

11. The workpiece dispensing apparatus of claim 10, wherein when the at least one sensor fails to detect the plurality of workpieces within the channel in a predefined period, the first track and the second track are caused to automatically separate from each other by a second distance, whereby the second distance is greater than the first distance, thereby clearing the channel of any of the plurality of workpieces to clear any jams.

12. The workpiece dispensing apparatus of claim 9, wherein the magazine comprises at least one sensor for detecting the plurality of workpieces within the channel.

13. The workpiece dispensing apparatus of claim 12, wherein when the at least one sensor fails to detect the plurality of workpieces within the magazine in apredefined period, the magazine is caused to automatically separate thereby clearing the channel of any of the plurality of workpieces to clear any jams.

14. The workpiece dispensing apparatus of any one of claims 1 to 13, wherein at least one of the plurality of workpieces is a fastener.

15. The workpiece dispensing apparatus of claim 14, wherein the fastener is at least one of a clip, a nut, a bolt, a screw, a dowel, and a nail.

16. An automated workpiece insertion assembly comprising:at least one workpiece dispensing apparatus comprising:a hopper for receiving a plurality of workpieces; a guiding mechanism for guiding the plurality of workpieces from the hopper to an exit port, wherein the guiding mechanism comprises a first track and a second track separated from each other by a first distance and defining a channel therebetween, the channel having a shape to maintain the plurality of workpieces in a first orientation;means for introducing the plurality of workpieces into the channel;means for causing the plurality of workpieces to move along the guiding mechanism towards the exit port; and a workpiece insertion tool comprising a magazine for receiving the plurality of workpieces from the exit port, wherein the workpiece insertion tool is configured to drive the plurality of workpieces into a component.

17. The automated workpiece insertion assembly of claim 16, wherein the guiding mechanism comprises at least one sensor for detecting the plurality of workpieces within the channel, and wherein when the at least one sensor fails to detect the plurality of workpieces within the channel in a predefined period, the first track and the second track are caused to automatically separate from each other by asecond distance, whereby the second distance is greater than the first distance, thereby clearing the channel of any of the plurality of workpieces to clear any jams.

18. The automated workpiece insertion assembly of claim 16 or claim 17, wherein the workpiece insertion tool 16 is moveable in an X-Y plane of a gantry stage.

19. The automated workpiece insertion assembly of any one of claims 16 to 18, wherein at least one of the plurality of workpieces is a fastener.

20. The automated workpiece insertion assembly of claim 19, wherein the fastener is at least one of a clip, a nut, a bolt, a screw, a dowel, and a nail.

21. A workpiece dispensing apparatus comprising:a rotatable hopper configured to receive a plurality of workpieces; a guiding assembly comprising a horizontal portion and a vertical portion, wherein the horizontal portion and the vertical portion comprise a first rail and a second rail defining a channel shaped and sized to support the plurality of workpieces in a first orientation, the first rail and a second rail being separated by a first distance;a vibrator operatively coupled to at least one of the rails and configured to advance the workpieces along the channel;a vertical portion coupled to the guiding assembly, wherein the vertical portion receives the plurality of workpieces and maintains the plurality of workpieces in a second orientation;a sensor positioned along the vertical portion to detect workpiece flow and a jam condition; anda separation actuator responsive to the jam condition, wherein the separation actuator is configured to translate the first rail away from the second rail from the first distance to a second distance, such that the second distance is greater than the first distance, to clear the jam.

22. The workpiece dispensing apparatus of claim 21, wherein the separation actuator comprises at least one of a pneumatic actuator, an electric solenoid and an electric motor.

23. The workpiece dispensing apparatus of claim 21, further comprising brushes affixed to the rotating hopper to cause mis-orientated clips to be pushed off and reduce the possibility of jams.

24. The workpiece dispensing apparatus of claim 23, wherein the brushes comprise at least one of metallic materials and non-metallic materials.

25. The workpiece dispensing apparatus of claim 21, wherein the first rail and the second rail are positioned at an angle between 1 degree and 30 degrees from a horizontal plane to assist the workpieces advance along the channel toward an exit.

26. The workpiece dispensing apparatus of claim 21, wherein the first distance is greater than or equal to a width of the workpiece to allow mis-orientated workpieces to fall through the channel.

27. The workpiece dispensing apparatus of claim 21, wherein the second distance is greater than the maximum width of the workpiece to allow workpieces to fall through the channel.

28. The workpiece dispensing apparatus of claim 11, wherein the vibrator comprises at least one of a voice coil actuator, an electric motor vibrator and pneumatic motor vibrator.

29. A workpiece dispensing apparatus comprising:a rotatable hopper having a plurality of workpieces;a guiding assembly for receiving the plurality of workpieces, wherein the guiding assembly comprises a horizontal portion within the hopper and a vertical portion, and wherein the guiding assembly comprises a first rail and a second rail defining a channel shaped and sized to support the plurality of workpieces in a first orientation;a sensor configured to detect the workpieces passing in the vertical portion onto a vertical stack and configured to detect when the vertical stack is full of the plurality of workpieces; and whereby when a workpiece does not pass by in a predefined amount of time then an anti -jam mode is triggered.

30. The workpiece dispensing apparatus of claim 29, further comprising a vibrator actuable to initiate a first vibration at a first frequency to cause the plurality of workpieces to travel forward on the guiding assembly.

31. The workpiece dispensing apparatus of claim 30, wherein when the anti-jam mode is triggered the vibrator is actuable to initiate a second vibration at a second frequency to cause the workpieces to travel backwards on the guiding assembly, and the first rail and the second rail are actuated to separate causing the plurality of workpieces on the horizontal portion to fall back into the hopper and the workpieces in the vertical portion to fall beneath the workpiece dispensing apparatus.

32. The workpiece dispensing apparatus of claim 31, wherein the vibrator is actuable to initiate the first vibration at the first frequency to cause the plurality of workpieces to travel forward on the guiding assembly, and if no workpieces are detected in the predefined amount of time then the anti -jam mode is triggered, and the vibrator is actuable to initiate the second vibration at the second frequency to cause the workpieces to travel backwards on the guiding assembly, and the first rail and the second rail are actuated to separate causing the plurality of workpieces on the horizontal portion to fall back into the hopper and the plurality of workpieces in the vertical portion to fall beneath the workpiece dispensing apparatus.

33. The workpiece dispensing apparatus of claim 32, wherein the vibrator is actuable to initiate the first vibration at the first frequency to cause the plurality of workpieces to travel forward on the guiding assembly, and if the plurality of workpieces are detected in the predefined amount of time then the anti -jam mode is clear and normal operation resumes.

34. A magazine assembly having a first magazine portion and a second magazine portion, the magazine assembly comprising:a vertical chute defined within the first magazine portion and a second magazine portion, the vertical portion configured to receive workpieces in a second orientation from a workpiece dispensing apparatus;a rotary plunger having a workpiece-engaging tip and configured to rotate and translate to withdraw a lowermost workpiece from the stack and transfer the workpieces into a spring-loaded chamber that constrains the workpiece in a third orientation for pickup by an insertion tool;at least one sensor positioned along the vertical chute to detect workpiece level; anda separation actuator configured, responsive to a jam condition detected by the sensor, to translate the first magazine away from the second magazine from a spacing di to a spacing d2, whereby the spacing d2 is greater than spacing di to clear the jam condition.

35. The magazine assembly of claim 34, wherein the rotary plunger is configured to rotatably actuate 90 degrees or greater.

36. The magazine assembly of claim 34, wherein rotary plunger from claim 1 actuated by either a pneumatic rotary actuator or an electric motor.

37. The magazine assembly of claim 34, wherein the separation actuator comprises at least one of a pneumatic actuator, an electric solenoid, and an electric motor.

38. A magazine assembly associated with a workpiece dispensing apparatus, the magazine assembly comprising:a first magazine portion and a second magazine portion; a vertical chute defined within the first magazine portion and a second magazine portion, the vertical portion configured to receive workpieces in a second orientation from a workpiece dispensing apparatus;a rotary plunger having a workpiece-engaging tip and configured torotate and translate to withdraw a lowermost workpiece from the stack and transfer the workpieces into a spring-loaded chamber that constrains the workpiece in a third orientation for pickup by an insertion tool;at least one first sensor positioned along the vertical chute to detect a high level of the workpieces in the vertical chute;at least one second sensor positioned along the vertical chute to detect a low level of the workpieces in the vertical chute;at least one third sensor configured to detect the actuation of the rotary plunger to transfer the workpieces into the spring-loaded chamber, and when the rotary plunger does not meet full stroke for transferring the workpieces, a jam condition is detected by the at least one third sensor; a separation actuator configured, responsive to a jam condition detectedby the sensor, to translate the first magazine away from the second magazine from a spacing di to a spacing 2, whereby the spacing t / 2 is greater than spacing di, thereby clearing the jam condition.

39. The magazine assembly of claim 38, wherein if during a magazine refill sequence the at least one first sensor associated with the vertical chute is triggered and the at least one first sensor associated with at least one of the magazine portions is not triggered, then a jam has occurred in the magazine, and a magazine antijam sequence is initiated.

40. The magazine assembly of claim 38, wherein if during a magazine refill sequence the at least one first sensor associated with at least one of the magazine portions does not trigger to dictate that new workpieces have entered the magazine then the magazine antijam sequence is triggered.

41. The magazine assembly of claim 40, wherein if during a magazine refill sequence the at least one first sensor associated with at least one of the magazine portions does not trigger a second time then a feeder antijam sequence is initiated.

42. The magazine assembly of claim 41, wherein if during a magazine refill sequence a third jam in a row is detected then the workpiece dispensing apparatus enters fault state.

43. An automated workpiece insertion system comprising:the workpiece dispensing apparatus of any one of claims 21 to 32; the magazine assembly of any one of claims 34 to 43; and a multi-axis insertion head movable in a X-Y axis and along a Z-axis with a rotatable R-axis, wherein the head is configured to receive the workpieces from the magazine assembly and insert the workpiece into a component.

44. The automated insertion system of claim 43, further comprising a plurality of workpiece dispensing apparatuses to create redundancy for maintenance, repairs, replacement or for additional hopper volume.

45. The automated insertion system of claim 44, when one of the plurality of workpiece dispensing apparatuses is undergoing refilling, maintenance or undergoing a sequence to free a jam, then another one of the plurality of workpiece dispensing apparatuses is employed.

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