PRODUCT ASSEMBLY SYSTEM AND CONTROL SOFTWARE

• US 20110125307A1
• Filed: 11/20/2009
• Published: 05/26/2011
• Est. Priority Date: 11/20/2009
• Status: Active Grant

• Current Assignee: AGR Automation Ltd.
• Original Assignee: AGR Automation Ltd.
• Inventors: McGill, Ronald Arron, Dickson, Craig Alexander
• Granted Patent: US 8,626,329 B2
• Time in Patent Office: Days
• US Class Current: 700/112
• CPC Class Codes: A21B 1/46 with surfaces suspended from an endless conveyor or a revolving wheel
• CPC Class Codes: B23P 21/004 the units passing two or more work-stations whilst being composed
• CPC Class Codes: B23Q 37/005 Modular base frames
• CPC Class Codes: B65B 43/52 using roller-ways or endless conveyors
• CPC Class Codes: B65G 2207/30 Modular constructions
• CPC Class Codes: B65G 37/02 Flow-sheets for conveyor combinations in warehouses, magazines or workshops
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
• CPC Class Codes: H01L 21/67276 Production flow monitoring, e.g. for increasing throughput program-control systems per se G05B19/00, e.g. total factory control G05B19/418
• CPC Class Codes: H05K 13/0061 Tools for holding the circuit boards during processing; handling transport of printed circuit boards
• CPC Class Codes: H05K 13/04 Mounting of components , e.g. of leadless components

Abstract

An improved assembly, test, packaging and/or processing system and a control system, each of which may be expanded or reduced in size, capability and/or capacity on a modular basis to suit or adapt to a number of different applications. The product assembly, test, packaging and/or processing system comprises a number of modules which are assembled and arranged as required. Pallets move between stations on the modules along track portions which cooperate with track portions on adjacent modules so other modules can be added without affecting the movement of the pallets. When those modules are added or removed, or when stations are added or removed, corresponding controllers in the control system are also added or removed.

Claims

1. A product assembly, test, packaging and/or processing system comprising:

at least one pallet on which to locate a product within the system;

a plurality of modules, each of said modules comprising a work surface upon which to mount one or more product assembly, test, packaging or processing stations; and

a track on which the at least one pallet is mounted and along which the pallet is moved from one tool to another;

a first of the modules comprising a first portion of the track and removeably connected to a second module comprising a second portion of the track and the track portions cooperating to allow the at least one pallet to move therebetween.

2. The system of claim 1, further comprising a plurality of linear motors and a plurality of pallets, each pallet having a magnet mounted and positioned thereon to interact with the linear motors to form a linear drive which moves the pallets along the track.

3. The system of claim 2, wherein each pallet comprises one or more bearings to aid movement of the pallet along the track.

4. The system of claim 2, wherein each pallet comprises at least two bearings positioned on opposite sides of the track and engaging said opposite sides of the track.

5. The system of claim 2, wherein the system further comprises a position controller to control the position of the plurality of pallets by controlling the interaction between the linear motors and the magnets mounted on said plurality of pallets.

6. The system of claim 1, further comprising one or more lead screw systems to move the at least one pallet.

7. The system of claim 1, wherein each of the one or more pallets comprises a radio frequency identification (RFID) tag.

8. The system of claim 1, wherein the position controller controls the distance between successive pallets to provide a variable pitch width.

9. The system of claim 1, further comprising a third module comprising a third portion of the track, whereby the third module is added to the system by removeably connecting the third module to one or both of the first and second modules, one or both of the first and second portions of track cooperating with the third portion of track to allow the at least one pallet to move between respective modules.

10. The system of claim 9, wherein the first, second and/or third modules comprise one or more linear motors aligned with an adjacent linear motor of the same or a connected module to allow continuous movement of the at least one pallet from one portion of the track to the next.

11. The system of claim 1, wherein the track forms a continuous loop to allow the at least one pallet to loop repeatedly around the system.

12. The system of claim 1, comprising a u-shaped track portion and a mechanical return wheel to interact with a pressure foot fitted to the rear of the at least one pallet and drive the at least one pallet around the u-shaped track portion.

13. The system of claim 1, comprising a u-shaped track portion and a corresponding curved linear motor or plurality of tangentially arranged straight linear motors.

14. The system of claim 1, wherein each of the modules comprises an integrated moveable guard, the integrated moveable guard of each module adapted to cooperate with the integrated moveable guard of an adjoining module to provide the system with a continuous moveable guard.

15. The system of claim 14, wherein the continuous moveable guard or any one of the integrated moveable guards is automatically locked in a closed position when the system is in operation.

16. The system of claim 14, wherein each of the integrated moveable guards comprise a gull-wing door.

17. The system of claim 1, wherein the work surfaces comprise adjustable station mounting rails to mount one or more product assembly, test, packaging or processing stations thereon.

18. A control system for controlling a product assembly, test, packaging and/or processing system, the control system comprising:

a position controller to control the position of at least one pallet within the system; and

one or more controllers to control the operation of each station on each module of the system;

wherein integration of an additional station is achieved by;

adapting the controller to control the additional station or adding another controller to the control system to control the additional station; and

providing the position controller with position information relating to the additional station.

19. The control system of claim 18, comprising a programmable logic controller having a plurality of controllers, said controllers including the position controller and at least one station controller.

20. The control system of claim 19, wherein the programmable logic controller is adapted to control an additional station by adding an additional corresponding station controller.

21. The control system of claim 18, comprising a plurality of inactive station controllers, wherein integration of an additional station is achieved by activating at least one of said inactive station controllers.

22. The control system of claim 18, wherein the one or more controllers provide an interface with one or more localised station controllers.

23. The control system of claim 18, wherein the control system creates a station controller based on a set of station parameters received by the control system.

24. The control system of claim 18, further comprising a human computer interface to display information relating to the system, and to receive commands and/or parameters relating to the operation of the system.

25. A computer program product containing one or more sequences of machine-readable instructions for a programmable logic controller or a computer, the instructions being adapted to cause one or more processors of the programmable logic controller or the computer to provide the control system of any of claims 18 to 24.