Assembly system for monitoring proper fastening of an article of assembly at more than one location
DC CAFCFirst Claim
1. An assembly system for assembling articles of assembly, each article of assembly having a plurality of fastening locations including at least first and second fastening locations in spaced apart relation, comprising:
- a fixture holding the article of assembly;
a plurality of targets including at least a first target fixed relative to the fixture, corresponding to the first fastening location, and a second target fixed relative to the fixture, the second target corresponding to the second fastening location, the second target having a different characteristic than the first target;
a fastening tool adapted to fasten fasteners into the article of assembly at the first and second fastening locations, the fastening tool having a first position relative to the fixture in which the fastening tool is in position to fasten a fastener at the first location, and a second position relative to the fixture in which the fastening tool is in position to fasten a fastener at the second location;
a target sensor fixed relative to the fastening tool along at least one axis, the target sensor sensing the first target when the fastening tool is in the first position, the target sensor sensing the second target when the fastening tool is in the second position, the target sensor providing a target output differentiating between the first and second targets and indicating when the fastening tool is in either of the first fastening location and the second fastening location; and
an electronic controller in communication with the target sensor utilizing said target output to check a quality characteristic of manual fastening operations facilitated by the fastening tool at the plurality of fastening locations, wherein the fastening tool moves independent of the electronic controller and is not controllably positioned thereby.
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Accused Products
Abstract
A more reliable and fool-proof method and apparatus for assembling an article of assembly (e.g. with predetermined screw torque requirements) in which the article of assembly has multiple fastening locations. The method comprises holding the article of assembly fixed while providing at least two different types of targets fixed relative to the article of assembly that correspond to the individual fastening locations. Fasteners are fastened into the article of assembly at the fastening locations. When fastening is occurring at one of the fastening locations, one of the targets is being sensed. Based on the target sensed, a target output is generated that differentiates between different types of targets thereby indicating fastening location of the fastening tool. The electronic target output is used for electronic control such as for stopping a conveyor to keep the article of assembly at an assembly station until the fastening operations have been completed.
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Citations
49 Claims
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1. An assembly system for assembling articles of assembly, each article of assembly having a plurality of fastening locations including at least first and second fastening locations in spaced apart relation, comprising:
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a fixture holding the article of assembly; a plurality of targets including at least a first target fixed relative to the fixture, corresponding to the first fastening location, and a second target fixed relative to the fixture, the second target corresponding to the second fastening location, the second target having a different characteristic than the first target; a fastening tool adapted to fasten fasteners into the article of assembly at the first and second fastening locations, the fastening tool having a first position relative to the fixture in which the fastening tool is in position to fasten a fastener at the first location, and a second position relative to the fixture in which the fastening tool is in position to fasten a fastener at the second location; a target sensor fixed relative to the fastening tool along at least one axis, the target sensor sensing the first target when the fastening tool is in the first position, the target sensor sensing the second target when the fastening tool is in the second position, the target sensor providing a target output differentiating between the first and second targets and indicating when the fastening tool is in either of the first fastening location and the second fastening location; and an electronic controller in communication with the target sensor utilizing said target output to check a quality characteristic of manual fastening operations facilitated by the fastening tool at the plurality of fastening locations, wherein the fastening tool moves independent of the electronic controller and is not controllably positioned thereby. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 25)
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13. An assembly system for assembling articles of assembly, each article of assembly having a plurality of fastening locations including at least first and second fastening locations in spaced apart relation, comprising:
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a fixture holding the article of assembly; a plurality of targets including at least a first target fixed relative to the fixture, corresponding to the first fastening location, and a second target fixed relative to the fixture, the second target corresponding to the second fastening location, the second target having a different characteristic than the first target; a fastening tool adapted to fasten fasteners into the article of assembly at the first and second fastening locations, the fastening tool having a first position relative to the fixture in which the fastening tool is in position to fasten a fastener at the first location, and a second position relative to the fixture in which the fastening tool is in position to fasten a fastener at the second location; a target sensor fixed relative to the fastening tool along at least one axis, the target sensor sensing the first target when the fastening tool is in the first position, the target sensor sensing the second target when the fastening tool is in the second position, the target sensor providing a target output differentiating between the first and second targets and indicating when the fastening tool is in either of the first fastening location and the second fastening location; wherein the fixture is carried by a conveyor, the fastening tool being movable relative to the conveyor, further comprising an assembly station along the conveyor, the fixture being conveyed on the conveyor to the assembly station where the fixture is intermittently stopped by a stop mechanism for fastening by the fastening tool, further comprising an electronic controller in communication with the target sensor, the electronic controller monitoring the location of the fastening tool to ensure proper fastening of fasteners at the fastening locations; and wherein the electronic controller controls the stop mechanism, the electronic controller maintaining the fixture at the assembly station and not releasing the fixture for movement on the conveyor out of the assembly station until the fastening tool has properly fastened fasteners into the article of assembly at the fastening locations.
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14. An assembly system for assembling articles of assembly, each article of assembly having a plurality of fastening locations including at least first and second fastening locations in spaced apart relation, comprising:
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a fixture holding the article of assembly; a plurality of targets including at least a first target fixed relative to the fixture, corresponding to the first fastening location, and a second target fixed relative to the fixture, the second target corresponding to the second fastening location, the second target having a different characteristic than the first target; a fastening tool adapted to fasten fasteners into the article of assembly at the first and second fastening locations, the fastening tool having a first position relative to the fixture in which the fastening tool is in position to fasten a fastener at the first location, and a second position relative to the fixture in which the fastening tool is in position to fasten a fastener at the second location; a target sensor fixed relative to the fastening tool along at least one axis, the target sensor sensing the first target when the fastening tool is in the first position, the target sensor sensing the second target when the fastening tool is in the second position, the target sensor providing a target output differentiating between the first and second targets and indicating when the fastening tool is in either of the first fastening location and the second fastening location; an electronic controller in communication with the target sensor, the electronic controller monitoring the location of the fastening tool to ensure proper fastening of fasteners at the fastening locations; wherein the fixture is carried by a conveyor, the fastening tool being movable relative to the conveyor, further comprising an assembly station along the conveyor, the fixture being conveyed on the conveyor to the assembly station where the fixture is intermittently stopped by a stop mechanism for fastening by the fastening tool; and wherein the fasteners are threaded fasteners, the fastening tool having a torque monitor, the torque monitor providing an indication to the electronic controller of torque applied to the fasteners, the electronic controller having predetermined torque values for at least one of the fastening locations, the electronic controller determining the location of the fastening tool that corresponds to the indication of torque and providing an output indicating whether the predetermined torque values for at least one of the fastening locations have been reached. - View Dependent Claims (15)
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16. An assembly system for assembling articles of assembly, each article of assembly having a plurality of fastening locations including at least first and second fastening locations in spaced apart relation, comprising:
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a fixture holding the article of assembly; a plurality of targets including at least a first target fixed relative to the fixture, corresponding to the first fastening location, and a second target fixed relative to the fixture, the second target corresponding to the second fastening location, the second target having a different characteristic than the first target; a fastening tool adapted to fasten fasteners into the article of assembly at the first and second fastening locations, the fastening tool having a first position relative to the fixture in which the fastening tool is in position to fasten a fastener at the first location, and a second position relative to the fixture in which the fastening tool is in position to fasten a fastener at the second location; a target sensor fixed relative to the fastening tool along at least one axis, the target sensor sensing the first target when the fastening tool is in the first position, the target sensor sensing the second target when the fastening tool is in the second position, the target sensor providing a target output differentiating between the first and second targets and indicating when the fastening tool is in either of the first fastening location and the second fastening location; an electronic controller in communication with the target sensor, the electronic controller monitoring the location of the fastening tool to ensure proper fastening of fasteners at the fastening locations; and wherein the fastening tool comprises a fastening monitor indicating a fastening operation, wherein the electronic controller has a predetermined sequence program requiring a predetermined sequence of fastening among the fastening locations, the electronic controller-monitoring the sequence of fastening based upon the target output, the electronic controller providing an output indicating whether the predetermined sequence has been achieved. - View Dependent Claims (17)
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18. An assembly system for assembling articles of assembly, each article of assembly having a plurality of fastening locations including at least first and second fastening locations in spaced apart relation, comprising:
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a fixture holding the article of assembly; a plurality of targets including at least a first target fixed relative to the fixture, corresponding to the first fastening location, and a second target fixed relative to the fixture, the second target corresponding to the second fastening location, the second target having a different characteristic than the first target; a fastening tool adapted to fasten fasteners into the article of assembly at the first and second fastening locations, the fastening tool having a first position relative to the fixture in which the fastening tool is in position to fasten a fastener at the first location, and a second position relative to the fixture in which the fastening tool is in position to fasten a fastener at the second location; a target sensor fixed relative to the fastening tool along at least one axis, the target sensor sensing the first target when the fastening tool is in the first position, the target sensor sensing the second target when the fastening tool is in the second position, the target sensor providing a target output differentiating between the first and second targets and indicating when the fastening tool is in either of the first fastening location and the second fastening location; where in the fixture is carried by a conveyor, the fastening tool being movable relative to the conveyor, and further comprising an assembly station along the conveyor, the conveyor transporting the fixtures through the assembly station substantially without stopping on a continuous basis; and wherein the assembly station has an input location receiving fixtures from an upstream station and an output location delivering fixtures to a downstream station, the fastening tool being movable horizontally along the conveyor between the input location and the output location, further comprising a fixture sensor in communication with fixtures passing through the assembly station, the fixture sensor having a fixture position output indicating when fixtures have exited the assembly station through the output location, an electronic controller in communication with the fixture sensor, the electronic controller outputting an alarm signal when one of the fixtures has exited the assembly station without proper fastening of fasteners at the fastening locations. - View Dependent Claims (19, 20)
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21. An assembly system for assembling articles of assembly, each article of assembly having a plurality of fastening locations including at least first and second fastening locations in spaced apart relation, comprising:
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a fixture holding the article of assembly; a plurality of targets including at least a first target fixed relative to the fixture, corresponding to the first fastening location, and a second target fixed relative to the fixture, the second target corresponding to the second fastening location, the second target having a different characteristic than the first target; a fastening tool adapted to fasten fasteners into the article of assembly at the first and second fastening locations, the fastening tool having a first position relative to the fixture in which the fastening tool is in position to fasten a fastener at the first location, and a second position relative to the fixture in which the fastening tool is in position to fasten a fastener at the second location; a target sensor fixed relative to the fastening tool along at least one axis, the target sensor sensing the first target when the fastening tool is in the first position, the target sensor sensing the second target when the fastening tool is in the second position, the target sensor providing a target output differentiating between the first and second targets and indicating when the fastening tool is in either of the first fastening location and the second fastening location; and wherein the fasteners are threaded fasteners, the fastening tool having a torque monitor, the torque monitor providing an indication to an electronic controller of torque applied to the fasteners, the electronic controller having predetermined torque values for at least one of the fastening locations, the electronic controller determining the location of the fastening tool that corresponds to the indication of torque and providing an output indicating whether the predetermined torque values for at least one of the fastening locations have been reached.
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22. An assembly system for assembling articles of assembly, each article of assembly having a plurality of fastening locations including at least first and second fastening locations in spaced apart relation, comprising:
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a fixture holding the article of assembly; a plurality of targets including at least a first target fixed relative to the fixture, corresponding to the first fastening location, and a second target fixed relative to the fixture, the second target corresponding to the second fastening location, the second target having a different characteristics than the first target; a fastening tool adapted to fasten fasteners into the article of assembly at the first and second fastening locations, the fastening tool having a first position relative to the fixture in which the fastening tool is in position to fasten a fastener at the first location, and a second position relative to the fixture in which the fastening tool is in position to fasten a fastener at the second location; a target sensor fixed relative to the fastening tool along at least one axis, the target sensor sensing the first target when the fastening tool is in the first position, the target sensor sensing the second target when the fastening tool is in the second position, the target sensor providing a target output differentiating between the first and second targets and indicating when the fastening tool is in either of the first fastening location and the second fastening location; and wherein the fastening tool plunges along a fastening axis perpendicular to said plane, the laser and laser sensing device remaining stationary during plunging of the fastening tool. - View Dependent Claims (23)
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24. An assembly system for assembling articles of assembly, each article of assembly having a plurality of fastening locations including at least first and second fastening locations in spaced apart relation, comprising:
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a fixture holding the article of assembly; a fastening tool adapted to fasten fasteners into the article of assembly at the first and second fastening locations, the fastening tool having a first position relative to the fixture in which the fastening tool is in position to fasten a fastener at the first location, and a second position relative to the fixture in which the fastening tool is in position to fasten a fastener at the second location; at least one sensor providing a sensor output indicating when the fastening tool is the first and second fastening locations; an electronic controller in communication with the at least one sensor, the electronic controller monitoring the location of the fastening tool to ensure proper fastening of fasteners at the fastening locations; and wherein the fastening tool comprises a fastening monitor indicating a fastening operation, wherein the electronic controller has a predetermined sequence program requiring a predetermined sequence of fastening among the fastening locations, the electronic controller monitoring the sequence of fastening based upon the sensor output, the electronic controller providing an output indicating whether the predetermined sequence has been achieved.
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26. An assembly system for assembling components of an article of assembly, comprising:
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first and second physically separate components that, when assembled together, form at least a portion of the article of assembly, wherein (a) a single set of discrete portions of the first and second components, when placed together, form at least a single process site consisting of a plurality of fastening locations within the single process site including at least first and second fastening locations, (b) each of the first and second fastening locations consists of a single opening for receiving a single fastener that, when fastened in the single opening, partially assembles the first and second components together, and (c) wherein the article of assembly is structurally designed so that the first and second fastening locations are positioned within the single process site is spaced apart relation to each other such that a fastener must be inserted in the first fastening location before a fastener is inserted in the second fastening location to reduce the risk of structural failure of the assembled combination of the first and second components that would arise if a fastener were inserted in the second fastening location before a fastener were inserted in the first fastening location; a fixture holding the first and second components of the article of assembly in a predetermined position in which the first and second components are placed together to form the single process site; a fastening tool adapted to fasten fasteners into the single process site formed by the first and second components of the article of assembly, the fastening tool having a first position relative to the fixture in which the fastening tool is in position to fasten a fastener at the first fastening location, and a second position relative to the fixture in which the fastening tool is in position to fasten a fastener at the second fastening location; at least one sensor providing a sensor output indicating when the fastening tool is at the first and second fastening locations; an electronic controller in communication with the at least one sensor, the electronic controller monitoring the location of the fastening tool to ensure proper fastening of fasteners at the fastening locations and having stored in a memory thereof before an operator has commenced manual fastening using the fastening tool (a) data representative of the location of the first fastening location within the single process site together with first order data indicating that a fastener must be inserted in the first fastening location at a point in time before a fastener is inserted in the second fastening location, and (b) data representative of the location of the second fastening location within the single process site together with second order data indicating that a fastener must be inserted in the second fastening location at a point in time after a fastener has been inserted in the first fastening location, wherein the location data and the first and second order data for the first and second fastening locations form a predetermined fastening sequence for the single process site that must be followed in order for the first and second components to be assembled together in a manner that reduces the risk of structural failure of the assembled combination that would arise if a fastener were inserted in the second fastening location before a fastener were inserted in the first fastening location; wherein the fastening tool comprises a fastening monitor indicating a fastening operation, wherein the electronic controller has a predetermined sequence program that, when executed, requires the operator'"'"'s use of the fastening tool to conform to the predetermined sequence of fastening among the first and second fastening locations by the electronic controller (a) monitoring the sequence of fastening based upon the sensor output, (b) electronically comparing the sensed position of the fastening tool with the data representative of the location of the first and second fastening locations within the single process site to determine if the fastening tool is located in operative relation to one of the first and second fastening locations and then (c) using the order data associated with the one of the first and second fastening locations to (i) enable the fastening tool, when it is positioned in operative relation to the first fastening location, to insert a fastener in the first fastening location only if the operator has not inserted a fastener in the second fastening location, and (ii) enable the fastening tool, when it is positioned in operative relation to the second fastening location, only if the operator already has inserted a fastener in the first fastening location, wherein requiring that the operator'"'"'s use of the fastening tool conform to the predetermined sequence of fastening in the single process site reduces the risk of structural failure of the assembled combination that would arise if a fastener were inserted in the second fastening location before a fastener were inserted in the first fastening location; the electronic controller providing a sequence output indicating whether the predetermined fastening sequence has been achieved each time that the operator attempts to fasten a fastener in one of the first and second fastening locations; wherein the electronic controller also has stored in its memory first and second predetermined torque values that represent torque values that the operator is supposed to apply to fasteners inserted in the first and second fastening locations only when the operator'"'"'s use of the fastening tool conforms to the predetermined sequence of fastening; and wherein the execution of the predetermined sequence program by the electronic controller requires the predetermined sequence of fastening to be followed in the single process site and also (a) uses the fastening monitor to measure torque applied to a fastener as it is being inserted in the first fastening location and then compares the measured torque to the first predetermined torque value, (b) requires that the torque applied to the fastener located in the first fastening location equal the first predetermined torque value before the operator is allowed to insert a fastener in the second fastening location, which reduces the risk of structural failure of the assembled combination that would result if the operator were allowed to insert a fastener in the second fastening location when the torque applied to the first fastener does not equal the first predetermined torque value; (c) uses the fastening monitor to measure torque applied to a fastener as it is being inserted in the second fastening location and then compares the measured torque to the second predetermined torque value, and (d) requires that the torque applied to the fastener located in the second fastening location equal the second predetermined torque value after the first fastener has been inserted in the first fastening location at the first predetermined torque value, which reduces the risk of structural failure of the assembled combination that would result if the operator were allowed to complete assembly of the first and second components when the torque applied to the fastener inserted in the second fastening location did not equal the second predetermined torque value. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49)
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Specification