Quality control system and method thereof

• US 7,953,508 B2
• Filed: 04/01/2008
• Issued: 05/31/2011
• Est. Priority Date: 04/01/2008
• Status: Expired due to Fees

• Current Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Lee, Gary, Buse, Sorin, Dennis, Jason J.
• Primary Examiner(s): Bahta; Kidest
• Application Number:
  US12/060,527
• Publication Number:
  US 20090149983A1
• Time in Patent Office: 1,155 Days
• Field of Search: 700101-115, 700/73, 700/76, 700/89, 700/273, 705 8- 10
• US Class Current: 700/101
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/32179 Quality control, monitor production tool with multiple sensors
• CPC Class Codes: G05B 2219/32181 Monitor production, assembly apparatus with multiple sensors
• CPC Class Codes: G05B 2219/45055 Assembly
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A quality control system and method for monitoring an assembly operation is provided. The method can include: (1) providing an assembly line having a plurality of machines being assembled thereon; (2) providing a tool for performing an assembly operation; (3) performing a plurality of the assembly operations with the tool; (4) measuring a measurable parameter indicative of the performance of the tool for at least a subset of the plurality of assembly operations; (5) storing the measured values in an electronic format with a data collection device; (6) analyzing the measured values; and (7) providing a signal based on the analysis with the signal indicative of at least satisfactory or unsatisfactory performance of the tool. In some instances, the data collection device can provide for storing additional information and/or data with any particular stored measured value.

Claims

1. A method for monitoring an assembly operation, the method comprising:

providing a machine assembly line having a plurality of machines being assembled;

providing a power wrench for tightening a threaded fastener and being calibrated to provide torque within a specification limit, the tightening of the threaded fastener resulting in a measurement of torque applied to the threaded fastener by the power wrench;

performing a plurality of tightening operations on a plurality of threaded fasteners using the power wrench;

measuring the torque applied by the power wrench for at least a subset of the plurality of tightening operations, each measurement providing a torque value;

storing the torque values within a data collection device in an electronic format;

analyzing the measured torque values;

comparing the analysis of the measured torque values to at least one predefined torque value; and

providing a signal to a first level responder based on the comparison of the analysis of the measured torque values to the at least one predefined torque value, the signal indicative of the power wrench providing torque values within or without the specification limit.

2. The method of claim 1, wherein the data collection device provides for storing additional data with any particular stored measured value.

3. The method of claim 1, wherein the power wrench is an electronic torque wrench.

4. The method of claim 1, wherein the signal is provided to the first level responder by an email and/or page.

5. The method of claim 4, further including providing the signal in an escalating alarm format to a second level responder if the unsatisfactory signal provided to the first level responder is not responded to within a predetermined amount of time.

6. The method of claim 5, wherein the signal is provided to the second responder by an email and/or page.

7. The method of claim 1, further including uploading the stored torque values from the data collection device to a computer wherein the steps of analyzing and comparing the stored torque values are carried out by the computer.

8. The method of claim 3, wherein the electronic torque wrench is part of a robot for placing exterior panels onto a motor vehicle.