System and method for optimizing a production process using electromagnetic-based local positioning capabilities

• US 8,676,368 B2
• Filed: 10/19/2009
• Issued: 03/18/2014
• Est. Priority Date: 10/19/2009
• Status: Active Grant

• Current Assignee: Fives Cinetic Inc.
• Original Assignee: Fives Cinetic Inc.
• Inventors: Stencel, John, Loos, Henry Arthur Jr.
• Primary Examiner(s): Padmanabhan, Kavita
• Assistant Examiner(s): LOPEZ ALVAREZ, OLVIN
• Application Number:
  US12/581,217
• Publication Number:
  US 20110093110A1
• Time in Patent Office: 1,611 Days
• Field of Search: 700/108, 700/115, 700/110, 700/32, 700/11, 382/103, 382/105
• US Class Current: 700/108
• CPC Class Codes: B25B 21/00 Portable power-driven screw or nut setting or loosening tools; details or components, e.g. casings, bodies, of portable power-driven tools not particularly related to the operation performed B25F5/00; for mounting or dismounting wheels B60B29/006; Attachments for drilling apparatus serving the same purpose machines B23P19/06
• CPC Class Codes: B25B 23/14 Arrangement of torque limiters or torque indicators in wrenches or screwdrivers couplings for transmitting rotation or clutches F16D; devices for measuring torque per se G01L
• CPC Class Codes: G05B 19/41805 characterised by assembly
• CPC Class Codes: G05B 2219/31027 Computer assisted manual assembly CAA, display operation, tool, result
• CPC Class Codes: G05B 2219/37618 Observe, monitor position, posture of tool
• CPC Class Codes: G05B 2219/45127 Portable, hand drill
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A system includes a handheld tool for executing steps of a sequence within a work cell. An electromagnetic marker connected to the tool emits a magnetic field within the cell. A receptor detects the magnetic field and generates a raw position signal in response thereto. A control unit updates an assembly setting of the tool. The host executes a control action when a position determined using the raw data is not equal to an expected position in the sequence. A method calculates the present position of a torque wrench using magnetic fields generated by the marker and measured by a receptor array, and calculates a present position of the tool or a fastener. The present position of the fastener may be compared to an expected position in the calibrated sequence, and the torque wrench may be disabled when the fastener position is not equal to the expected position.

Claims

1. A system for optimizing a process within a work cell, wherein the process has a calibrated sequence, the system comprising:

a handheld tool configured to execute steps of the calibrated sequence with respect to a work piece;

an electromagnetic marker connected to the handheld tool, wherein the electromagnetic marker is configured to emit a calibrated magnetic field within the work cell;

a stationary electromagnetic receptor positioned in the work cell external to the handheld tool and adapted to measure the emitted calibrated magnetic field, and to generate a raw positional signal in response thereto;

a processing core in communication with the stationary electromagnetic receptor, the processing core being adapted for processing the raw positional signal to thereby calculate each of a position value and an attitude value in the form of yaw, pitch, and roll for the handheld tool;

a control unit that selectively updates a performance setting of the handheld tool;

a graphical user interface (GUI); and

a host machine in communication with the GUI, the control unit, and the processing core, wherein the host machine is operable for;

displaying, via the GUI, an expected position from the calibrated sequence;

continuously monitoring a present position of the handheld tool within the work cell using the position value and the attitude value;

comparing the present position of the handheld tool to the displayed expected position in the calibrated sequence;

comparing a current performance setting of the handheld tool to an expected performance setting corresponding to the displayed expected position; and

executing a control action, including temporarily disabling the handheld tool, when the present position of the handheld tool is not equal to the displayed expected position in the calibrated sequence, and updating the performance setting of the handheld tool via the control unit when the current performance setting is not equal to the expected performance setting.

2. The system of claim 1, wherein the calibrated magnetic field is used by the processing core to determine a location of each of the electromagnetic marker and the handheld tool along a respective X-axis, Y-axis, and Z-axis of the handheld tool.

3. The system of claim 1, wherein the handheld tool includes a rotatable shaft portion having a longitudinal axis, and wherein the electromagnetic marker has a circular cross section and is positioned adjacent to the rotatable shaft portion such that electromagnetic marker circumscribes the shaft and the longitudinal axis.

4. The system of claim 1, wherein the control action also includes activating an audio/visual device, including activating at least one of a lamp and a speaker.

5. The system of claim 1, wherein the host machine is operable for displaying a template of the work piece via the GUI, and for overlaying the template with an icon of the expected position.

6. A system for optimizing a fastener installation process within a work cell, the system comprising:

a handheld torque wrench adapted to install a threaded fastener into a work piece, the handheld torque wrench having a rotatable shaft that rotates about an axis of rotation;

an electromagnetic marker connected to the handheld torque wrench such that the axis of rotation passes through the electromagnetic marker, wherein the electromagnetic marker is adapted to emit calibrated magnetic fields in close proximity to the handheld torque wrench within the work cell;

a stationary array of electromagnetic receptors positioned in the work cell external to the handheld torque wrench and adapted to measure the emitted magnetic fields, and to generate a raw positional signal in response thereto;

a processing core in communication with the array of receptors, wherein the processing core is adapted for processing the positional signal to thereby calculate a position value and an attitude value in the form of yaw, pitch, and roll for the electromagnetic marker;

a fastener control unit (FCU) that selectively updates a performance setting of the handheld torque wrench;

a graphical user interface (GUI); and

a host machine in communication with the processing core, the FCU, the GUI, and the electromagnetic marker, wherein the host machine is operable for;

displaying, via the GUI, an expected position from a calibrated sequence;

continuously monitoring a present position of the handheld torque wrench using the position value and the attitude value;

calculating a present position of the threaded fastener using the present position of the handheld torque wrench;

comparing the present position of the threaded fastener to the displayed expected fastener position in a calibrated fastener sequence; and

executing at least one control action, including temporarily disabling the handheld torque wrench, when the present position of the threaded fastener is not equal to the expected fastener position, and updating the performance setting of the handheld torque wrench via the FCU when a current performance setting of the handheld torque wrench is not equal to an expected performance setting of the handheld torque wrench.

7. The system of claim 6, wherein the at least one control action further includes displaying a message to an operator of said torque wrench and activating an audible alarm.

8. The system of claim 6, wherein the electromagnetic marker has a circular cross section and is positioned adjacent to the rotatable shaft.

9. The system of claim 8, wherein the handheld torque wrench includes a butt-end and a grip portion, and wherein the electromagnetic marker is mounted to the butt-end adjacent to the grip portion such that the electromagnetic marker circumscribes the axis of rotation.

10. The system of claim 6, wherein the host machine is operable for displaying a template of the work piece via the GUI, and for overlaying the template with an icon of the expected position.

11. A method for optimizing a fastener installation process within a work cell, the method comprising:

emitting a calibrated magnetic field via an electromagnetic marker positioned within the work cell;

sensing the calibrated magnetic field via an electromagnetic receptor array, wherein one of the electromagnetic marker and the electromagnetic receptor array is connected to a handheld torque wrench;

generating a raw positional signal using the receptor array;

processing the raw positional signal using a processing core to thereby convert the raw position signal into a position value and an attitude value of the electromagnetic marker in the form of yaw, pitch, and roll; and

continuously monitoring a present position of the handheld torque wrench within the work cell, via a host machine, based on the position value and the attitude value;

comparing the present position of the handheld torque wrench to an expected position in a calibrated sequence;

displaying, via a graphical user interface (GUI), an expected position from a calibrated sequence;

comparing a current performance setting of the handheld torque wrench to an expected performance setting from the calibrated sequence; and

executing a control action, including temporarily disabling the handheld torque wrench, when the present position of the handheld torque wrench is not equal to the expected position in the calibrated sequence, and updating the performance setting of the handheld torque wrench via a fastener control unit when the current performance setting is not equal to the expected performance setting.

12. The method of claim 11, wherein executing a control action further includes:

detecting a present torque setting of the handheld torque wrench as the current performance setting;

comparing the present torque setting to a calibrated torque setting, wherein the calibrated torque setting is the expected performance setting; and

automatically updating the present torque setting to match the calibrated torque setting when the present torque setting is not equal to the calibrated torque setting.

13. The method of claim 11, wherein executing a control action further includes:

activating an audio/visual alarm device external to the work cell when said present position of said threaded fastener is not equal to the corresponding fastener position, wherein the audio/visual alarm device includes at least one of a lamp and a speaker.

14. The method of claim 11, wherein displaying an expected position from the calibrated sequence includes displaying a template of the work piece via the GUI, and overlaying the template with an icon of the expected position.