Intelligent assembly systems and methods

• US 6,553,321 B2
• Filed: 08/24/2001
• Issued: 04/22/2003
• Est. Priority Date: 08/24/2001
• Status: Expired due to Term

• Current Assignee: Intelligent Assembly LLC (Endpoint IP LLC)
• Original Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Inventors: Siegel, Robert P., OʼLeyar, Stephen C.
• Primary Examiner(s): Barlow, John
• Assistant Examiner(s): Sun, Xiuqin
• Application Number:
  US09/682,361
• Publication Number:
  US 20030040871A1
• Time in Patent Office: 606 Days
• Field of Search: 298/980.9, 294/070.8, 297/12, 395/600, 364/468.01, 702/33, 173/183, 707/10, 324/228
• US Class Current: 702/33
• CPC Class Codes: B23P 19/06 Screw or nut setting or loosening machines
• 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 2219/37434 Measuring vibration of machine or workpiece or tool
• CPC Class Codes: G05B 2219/45064 Assembly robot
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10T 29/497 Pre-usage process, e.g., preloading, aligning

Abstract

An intelligent assembly system for a manufacturing process using one or more sensors that provide information for controlling, monitoring and/or evaluating the process. One or more sensors may be mounted on a module assembly and/or on a powered tool device. The one or more sensors may sense a vibratory signature and/or electrical current during the process and supply information, such as a data signal, to a software program or other processor for processing. For example, using a database of stored data regarding vibratory signatures and/or electrical currents for one or more power tool devices used in the manufacturing process, the information may be compared and analyzed to determine if it is within a specified range. Results of such analysis may be transmitted to an operator and/or graphically displayed. The results and/or display may instruct the operator to continue with the manufacturing process or inspect the process step just completed for possible error.

Claims

1. A method for intelligent assembly, the method comprising the steps of:

inserting a fastener into an assembly;

sensing a signature characteristic of the insertion of the fastener;

evaluating the insertion of the fastener using the sensed signature characteristic;

wherein the evaluating step comprises;

counting a number of a plurality of insertions for at least one of an assembly process step and an entire assembly process;

comparing the counted number of a plurality of insertions with a desired number of plurality of insertions; and

determining whether the desired number of a plurality of insertions is made.

2. The method of claim 1, further comprising transmitting a result based on the evaluation of the insertion of the fastener.

3. The method of claim 2, further comprising displaying the transmitted result.

4. The method of claim 1, wherein the signature characteristic is a vibratory signature.

5. The method of claim 1, wherein the signature characteristic is an electrical signature.

6. The method of claim 1, wherein the evaluating step comprises determining whether the insertion of the fastener is a complete insertion.

7. The method of claim 1, wherein the evaluating step further comprises determining at least one of whether desired length fastener is used, whether a desired number of a plurality of washers is used and whether a desired thickness of washers is used.

8. The method of claim 1, wherein the evaluation of the insertion of the fastener comprises comparing the signature characteristic to a predetermined signature characteristic.

9. The method of claim 8, wherein the comparing step comprises:

accessing a database of predetermined signature characteristics; and

determining whether the signature characteristic of the insertion of the fastener is a sufficient match to one of the predetermined signature characteristics of the database.

10. The method of claim 9, further comprising creating the database of predetermined signature characteristics based on the assembly process.

11. An intelligent assembly system, comprising:

at least two parts to be assembled through insertion of at least one fastener;

at least one sensor associated with at least one of the parts to be assembled and arranged to sense a signature characteristic of the insertion of the fastener; and

a processor that evaluates the insertion of the fastener based on the sensed signature characteristic;

wherein the at least one sensor is at least temporarily mounted directly on at least one of the parts.

12. The system of claim 11, further comprising a shop floor control in communication with the processor.