Reconfigurable gantry tool and system

• US 5,920,974 A
• Filed: 09/01/1998
• Issued: 07/13/1999
• Est. Priority Date: 05/15/1997
• Status: Expired due to Fees

• Current Assignee: Northrop Grumman Systems Corporation (Northrop Grumman Corporation)
• Original Assignee: Northrop Grumman Corporation
• Inventors: Bullen, George Nicholas
• Primary Examiner(s): BRIGGS, WILLIAM R
• Application Number:
  US09/145,149
• Time in Patent Office: 315 Days
• Field of Search: 29/407.01, 29/524.1, 29/243.53, 29/34 B, 29/33 K, 29/28 A, 29/457, 29/430, 29/431, 29/525.2, 29/783, 29/791, 227/66, 227/58, 408/71, 408/234, 409/202, 409/211, 409/212, 409/213, 409/216, 409/221, 409/224, 409/235
• US Class Current: 29/33.00K
• CPC Class Codes: B23P 21/004 the units passing two or more work-stations whilst being composed
• CPC Class Codes: B23P 23/06 Metal-working plant comprising a number of associated machines or apparatus
• CPC Class Codes: B23P 2700/01 Aircraft parts
• CPC Class Codes: B23Q 1/015 Frames, beds, pillars
• CPC Class Codes: B23Q 37/00 Metal-working machines, or constructional combinations thereof, built-up from units designed so that at least some of the units can form parts of different machines or combinations; Units therefor in so far as the feature of interchangeability is important features relating to particular metal-working operations, see the relevant subclass, e.g. B23P23/00
• CPC Class Codes: B23Q 41/04 Features relating to relative arrangements of machines
• CPC Class Codes: Y10T 29/49829 Advancing work to successive stations [i.e., assembly line]
• CPC Class Codes: Y10T 29/5118 Riveting
• CPC Class Codes: Y10T 29/5191 Assembly
• CPC Class Codes: Y10T 29/534 Multiple station assembly or disassembly apparatus
• CPC Class Codes: Y10T 409/307728 including gantry-type cutter-carrier
• CPC Class Codes: Y10T 409/308288 including gantry-type cutter-carrier
• CPC Class Codes: Y10T 409/308792 Indexable

Abstract

The present invention is embodied in a reconfigurable gantry tool and a reconfigurable tool system. The reconfigurable tool includes a platform, a reconfigurable holding mechanism, a gantry frame, a multi-axis numerically controlled robotic tool, a multi-movement control device coupled to the mobile multi-axis tool, and a rotatable and translatable sine plate. The reconfigurable gantry tool system comprises a plurality of reconfigurable gantry tools strategically coupled to one another to form a non-matrix assembly line. Other tooling systems can be coupled to and/or within the reconfigurable gantry tool system for performing additional operations.

Claims

1. A method of performing tooling operations, comprising the steps of:

(a) placing a first workpiece within a work envelope of a first reconfigurable gantry tool;

(b) performing at least one tooling operation on said first workpiece;

(c) engaging, in a detachable manner, said first reconfigurable gantry tool with a second reconfigurable gantry tool by moving one of said first and second reconfigurable gantry tools toward the other of said first and second reconfigurable gantry tools;

(d) transferring said first workpiece to a work envelope of said second reconfigurable gantry tool; and

(e) repeating steps (a)-(d) for other reconfigurable gantry tools as necessary.

2. The method of claim 1, wherein said first reconfigurable gantry tool is aligned and engaged with said second reconfigurable gantry tool with a plurality of proximity sensors.

3. The method of claim 1, wherein said engaging step includes aligning said first reconfigurable gantry tool with said second reconfigurable gantry tool and performing said step with a self leveling system.

4. The method of claim 1, wherein said steps (a)-(e) are facilitated by a multi-movement control device coupled to said tools.

5. The method of claim 1, wherein said second reconfigurable gantry tool includes a second workpiece and wherein said transferring said first workpiece to a work envelope of said second reconfigurable gantry tool includes mating said first workpiece with said second workpiece.

6. The method of claim 1, wherein said engaging step comprises sensing position and location of said first reconfigurable gantry tool with respect to said second reconfigurable gantry tool and adjusting the first reconfigurable gantry tool accordingly for proper alignment.

7. An assembly line for assembling a structure comprised of workpieces, said assembly line comprising:

a plurality of interconnected reconfigurable gantry tools for processing said workpieces, each reconfigurable gantry tool comprising;

a movable platform for interconnecting corresponding reconfigurable gantry tools;

a sine plate rotatably and slidably coupled to said platform;

a numerical controlled gantry slidably coupled to said platform to allow multi-axis movement of a tool supported by said gantry for performing tooling operations on said workpiece; and

a multi-movement control device coupled to said platform, sine plate, and gantry for controlling movement of said coupled devices; and

a controller for controlling interaction between said reconfigurable gantry tools of said assembly line.

8. The system of claim 7, further comprising at least one other tool located within said interconnected reconfigurable gantry tools.

9. The system of claim 7, wherein each of said reconfigurable gantry tool is aligned and engaged with a corresponding reconfigurable gantry tool so that respective workpieces of each reconfigurable gantry tool are at least one of, (a) transferred to one another, and (b) mated with each other.

10. The system of claim 7, wherein said reconfigurable gantry tool platform further includes a self leveler.

11. The system of claim 7, wherein said gantry further includes an automatic locator for properly locating and aligning said gantry with a selected location on said workpiece.

12. The system of claim 7, wherein said gantry comprises:

a robotic arm having an end machine tool and a rotator for rotating said end machine tool about a rotational axis and a pivotor for pivoting said end machine tool about any pivot axis orthogonal to said rotational axis;

a vertical translation module coupled to said robotic arm and having a vertical movement device for translating said robotic arm along a Z axis;

a plurality of longitudinal translation modules coupled to said robotic arm and said platform and having a longitudinal movement device for translating said longitudinal translation modules along a Y axis of said platform; and

a transverse translation module coupled to said robotic arm and said vertical translation module and having a transverse movement device for translating said transverse translation module along an X axis.

13. The system of claim 12, wherein each of said translation modules further comprises:

a rail for supporting each of said respective module; and

a linear ballscrew threadedly engaged with each of said respective module.

14. The system of claim 12, wherein each of said movement device of each of said translation modules further comprises:

a motor connected to each of said respective translation module for moving each of said respective module.

15. The system of claim 14 further comprising:

a belt reduction drive connecting said motor to each of said respective translation module.

16. The system of claim 12, wherein said vertical translation module further comprises:

a secondary vertical translation module aligned parallel to said vertical translation module and connected to said vertical movement device.

17. The system of claim 12, wherein said control device comprises:

a controller for storing control signals for each of said respective movement device and for said machine tool, and sending said control signals to each of said respective movement device and said machine tool at predetermined intervals.

18. The system of claim 17, wherein said control signals for each of said respective movement device further comprise:

a set of cartesian coordinates for each of said respective movement devices; and

a set of angles for each of said rotator and pivotor.

19. The system of claim 18 wherein said control signals for said machine tool further comprise:

a set of machine tool operation instructions.

20. The system of claim 12, wherein:

each of said translation modules, rotator, and pivotor further comprises a sensor for measuring a position of each of said respective translation modules and a position of said machine tool about said rotational axis and said pivot axis, and sending a position signal;

a controller for storing control signals for each of said respective movement device and for said machine tool, and sending said control signals; and

a control module for receiving each of said respective control signals, sending each of said respective control signals to each of said respective movement devices and to said machine tool, receiving each of said respective sensor position signals, and sending position correction signals to each of said respective movement devices.

21. The system of claim 12 further comprising:

a ballrail mounted parallel to said transverse translation module on a side opposite to said vertical translation module;

a sliding device connected to said transverse translation module and engaging said ballrail so as to constrain transverse movement of said transverse translation module and to prevent vertical movement of said transverse translation module.