US20120006845A1 - Fastener clearing systems - Google Patents
Fastener clearing systems Download PDFInfo
- Publication number
- US20120006845A1 US20120006845A1 US13/236,594 US201113236594A US2012006845A1 US 20120006845 A1 US20120006845 A1 US 20120006845A1 US 201113236594 A US201113236594 A US 201113236594A US 2012006845 A1 US2012006845 A1 US 2012006845A1
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- US
- United States
- Prior art keywords
- component
- fastener
- catcher
- delivery conduit
- extractor
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J15/00—Riveting
- B21J15/10—Riveting machines
- B21J15/30—Particular elements, e.g. supports; Suspension equipment specially adapted for portable riveters
- B21J15/32—Devices for inserting or holding rivets in position with or without feeding arrangements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
- B23P19/001—Article feeders for assembling machines
- B23P19/003—Escapement mechanisms used therewith
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
- B23P19/001—Article feeders for assembling machines
- B23P19/004—Feeding the articles from hoppers to machines or dispensers
- B23P19/005—Feeding the articles from hoppers to machines or dispensers by using flowing gases
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P2700/00—Indexing scheme relating to the articles being treated, e.g. manufactured, repaired, assembled, connected or other operations covered in the subgroups
- B23P2700/01—Aircraft parts
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49947—Assembling or joining by applying separate fastener
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/53478—Means to assemble or disassemble with magazine supply
Definitions
- This invention relates generally to systems and methods for automated delivery of fasteners and, more specifically, to pneumatic fastener delivery systems.
- Automated fastener delivery systems in aeronautical applications should provide consistent operation.
- a typical aircraft will include thousands of fasteners, which must be installed quickly and cost-effectively.
- tools used to handle the fasteners may become fouled by contaminants, oils, or coatings that are carried by the fasteners.
- fasteners may adhere to tooling rather than releasing predictably.
- Lodged fasteners prevent consistent delivery of fasteners and cause delay when they must be removed by hand.
- a typical suction head creates a vacuum that draws the fastener into the suction head and retains the fastener. The suction head may then be moved to another location where the vacuum is deactivated and the fastener is allowed to fall under the force of gravity.
- the simplicity of operation and minimal moving parts of suction heads make them very cost effective.
- a fastener may remain within the grip of the suction head after the vacuum is deactivated. Accordingly, although suction heads are an effective material handling tool, there is room for improvement.
- the present invention is directed to methods and apparatus for automated delivery of fasteners to an installation tool.
- Embodiments of the invention enable consistent release of fasteners and other components from a suction head of fastener handling tooling in an automated fastener delivery system.
- an apparatus in one embodiment, includes one or more fastener storage devices and an unloading mechanism in communication with the fastener storage device.
- the unloading mechanism includes a fastener seat having a fluid channel coupled thereto.
- a pneumatic control system regulates air flow between a pressurized air source and the fluid channel. The control system generates both overpressure and vacuum within the fluid channel. Vacuum may be generated by pneumatic vacuum generators in fluid communication with the fluid channel. Overpressure may be generated by releasing pressurized air into the fluid channel through a backflow port.
- the backflow port is formed in a fitting securing first and second vacuum generators to one another.
- a pneumatic control system In operation, a pneumatic control system generates a vacuum within the fluid channel to draw at least one fastener from the fastener storage device into the fastener seat. The unloading mechanism is then moved to the delivery conduit. The control system then generates overpressure within the fluid channel to expel the fastener into the delivery conduit. In some embodiments, the vacuum is first deactivated and the fastener is allowed to fall into the delivery conduit. If the fastener fails to fall, then overpressure is generated within the fluid channel to expel the fastener. Whether the fastener falls may be determined by a proximity sensor secured on or near the delivery conduit.
- FIG. 1 is a perspective view of a portable fastener delivery system suitable for use with a fastener clearing system, in accordance with an embodiment of the present invention
- FIG. 2 is a perspective view of a delivery conduit, in accordance with an embodiment of the present invention.
- FIG. 3 is a perspective view of an extractor mechanism, in accordance with an embodiment of the present invention.
- FIG. 4 is a side view of an extractor catcher, in accordance with an embodiment of the present invention.
- FIG. 5 is a process flow diagram of a method for using a fastener clearing system, in accordance with an embodiment of the present invention.
- the present invention relates to systems and methods for automated delivery of fasteners to a fastener installation tool, and more specifically, to improved fastener clearing systems and methods.
- the present invention is suitable for use in fastener delivery systems, including the type generally disclosed, for example, in U.S. Pat. No. 6,688,489 issued to Daniel D. Bloch et al., which is incorporated herein by reference.
- Many specific details of certain embodiments of the invention are set forth in the following description and in FIGS. 1 through 5 to provide a thorough understanding of such embodiments.
- One skilled in the art, however, will understand that the present invention may have additional embodiments, or that the present invention may be practiced without one or more of the details described in the following description.
- a fastener delivery system 10 generally includes an unloading mechanism 12 in communication with a fastener storage device 14 , wherein a control system 16 causes the unloading mechanism 12 to remove a fastener having a specific configuration from the fastener storage device 14 and transport the fastener to a delivery conduit 18 , wherein the fastener is delivered to a work station.
- the fastener delivery system 10 may be disposed within a portable platform, such as a mobile cart 20 , so that a variety of fasteners may be delivered to a plurality of work stations located throughout a manufacturing facility.
- the fastener delivery system 10 generally removes and delivers fasteners using a pneumatic source 22 .
- the pneumatic source 22 is shop air at 90 psi (pounds per square inch).
- the pneumatic source 22 may be activated by the control system 16 and is in communication with both the unloading mechanism 12 and the delivery conduit 18 through flexible tubing 24 .
- the fittings that connect the pneumatic source 22 and the flexible tubing 24 are not shown for clarity.
- the pneumatic source 22 activates one or a plurality of vacuum generators 26 to remove a fastener from the fastener storage device 14 and secure the fastener within the unloading mechanism 12 .
- the fastener storage device 14 may include a plurality of tubes 28 .
- the tubes 28 may bear seals 30 for engaging the unloading mechanism 12 .
- the delivery conduit 18 further comprises a drop station 32 in communication with a first fastener delivery tube 34 and a second fastener delivery tube 36 .
- the drop station 32 further comprises a plurality of drop plates 38 that define chutes 40 , through which the fasteners are dropped as previously described.
- the chutes 40 are tapered, although a variety of shapes may be employed to effectuate transport of the fastener through the delivery conduit 18 .
- the plurality of drop plates 38 are employed to facilitate rapid interchangeability for a variety of fastener configurations. Alternately, a single drop plate may be employed rather than the plurality of drop plates 38 .
- the first fastener delivery tube 34 extends from the drop station 32 and is in communication with the second fastener delivery tube 36 .
- a fastener is transported through the first fastener delivery tube 34 by gravity until the fastener passes beyond a proximity sensor 42 .
- the proximity sensor 42 detects the presence of a fastener
- the proximity sensor 42 notifies the control system 16 , and the control system 16 then activates the pneumatic source 22 ( FIG. 1 ).
- the pneumatic source 22 provides pressurized air through the second fastener delivery tube 36 to deliver the fastener to the work station.
- the workstation may include an end effector suitable for installing the fastener.
- the first fastener delivery tube 34 may be rigid in order to facilitate efficient transport of the fastener by gravity. Accordingly, in one particular embodiment, the first fastener delivery tube 34 is fabricated from aluminum tube stock or other rigid material commonly known in the art.
- the second fastener delivery tube 36 may be flexible so that the fastener may be delivered to a plurality of work stations throughout a manufacturing facility. Accordingly, the length of the second fastener delivery tube 36 may be varied to accommodate the required distance from the portable fastener delivery system 10 to the work station.
- the amount of time that the pneumatic source 22 provides pressurized air through the second fastener delivery tube 36 is a function of the length of the delivery tube and the fastener configuration being delivered, and therefore, the amount of time that pneumatic source 22 is activated must be adjusted according to the length of the second fastener delivery tube 36 .
- the inner diameter of the second fastener delivery tube 36 should be sized appropriately to prevent tumbling of the fastener along the length thereof, which is generally a function of the overall size of the fastener.
- the inner diameter of the second fastener delivery tube 36 may desirably be slightly larger than the diameter of the fastener head yet smaller than the overall length of the fastener to prevent tumbling.
- the second fastener delivery tube 36 may be fabricated from relatively soft and flexible plastic such as nylon with a relatively smooth inner surface to minimize friction between the fastener and the inner wall of the second fastener delivery tube 36 .
- the unloading mechanism 12 generally comprises an extractor tool 44 having an extractor catcher 46 attached thereto.
- the vacuum generators 26 are disposed at an upper end of the extractor tool 44 and the extractor catcher 46 is disposed at a lower end of the extractor tool 44 .
- the portable fastener delivery system 10 may comprise any number of extractor tools 44 and vacuum generators 26 to remove fasteners in accordance with specific operating requirements. Therefore, the illustrated embodiment which uses two (2) extractor tools 44 with two (2) vacuum generators 26 each should not be construed as limiting the scope of the present invention.
- the unloading mechanism 12 is positioned adjacent the fastener storage device 14 using a linear X-Y positioner 48 that is activated by the control system 16 ( FIG. 1 ). More specifically, the linear X-Y positioner 48 positions an extractor catcher 46 of the unloading mechanism 12 ( FIG. 3 ) adjacent the appropriate fastener storage tube 28 that contains the requested fastener. Accordingly, the X and Y position of each fastener storage tube 28 is stored within the control system 16 as described in greater detail below. Additionally, the extractor tool 44 , along with the extractor catcher 46 attached thereto, may be translated in the vertical direction with a vertical axis positioner 50 as shown.
- the extractor catcher 46 is translated in the vertical direction in order to engage the extractor catcher 46 with the fastener storage tube 28 for removal of the requested fastener as described in further detail below.
- the vertical axis positioner 50 may be pneumatically controlled and is therefore activated by the pneumatic source 22 .
- control system 16 activates the linear X-Y positioner 48 to position the unloading mechanism 12 adjacent the fastener storage device 14 , and more specifically, to position an extractor catcher 46 adjacent the appropriate fastener storage tube 28 .
- the vertical axis positioner 50 moves the extractor tool 44 in the vertical direction until the extractor catcher 46 abuts the seal 30 .
- the pneumatic source 22 (not shown) then activates the vacuum generators 26 , and as a result, one or more of the fasteners 52 within the fastener storage tube 28 move up against the extractor catcher 46 .
- a seal may be created at the interface between the top fastener 52 and the extractor catcher 46 , thereby causing the remaining fasteners 52 to drop back into the fastener storage tube 28 .
- the unloading mechanism 12 removes the top fastener 52 from the fastener storage device 14 without the need for a separate fastener escapement mechanism.
- the fastener 52 abuts an upper surface 54 of the extractor catcher 46 , and may create a sealed (or at least partially sealed) connection therebetween. In operation, the at least partially sealed connection causes the remaining fasteners to drop back into the fastener storage tube.
- the extractor catcher 46 also comprises a tapered inner surface 56 to further facilitate ease of removal of the fastener 52 from the fastener storage device 14 .
- the upper surface 54 of the extractor catcher 46 may be modified to accommodate various types of fastener heads.
- a channel 58 opens into the upper surface 54 of the extractor catcher 46 and is in fluid communication with the vacuum ports of the vacuum generators 26 .
- the fastener 52 may tend to adhere to the surface 54 .
- Adhesion may be caused, for example, by contaminants such as oil or dust within the extractor catcher 46 .
- Adhesion may also result from coatings applied to a fastener 52 , such as a cetyl alcohol coating applied to prevent galvanic corrosion at interfaces between dissimilar metals. Where adhesion occurs, gravity may be insufficient to dislodge the fastener 52 from the extractor catcher 46 .
- the extractor tool 44 may include a backflow port 60 fluidly coupled to the upper surface 54 of the extractor catcher 46 .
- the blackflow port 60 may be coupled to a source of pressurized gas.
- one of the flexible tubes 24 may connect the backflow port 60 to the pneumatic source 22 .
- pressurized air may be released through the backflow port 60 to remove the fastener.
- pressurized air is automatically and systematically released to ensure release of each fastener 52 each time the vacuum is released to release the fastener 52 from the extractor catcher 46 .
- pressurized air is released through the backflow port 60 only in instances where the fastener 52 fails to fall from the extractor catcher 46 .
- the control system 16 typically regulates the release of air through the backflow port 60 .
- the backflow port 60 is formed in a fitting 62 ( FIG. 3 ) which secures the two vacuum generators 26 to one another. Forming the port 60 in the fitting 62 eliminates the need for separate parts for the port 60 and for securing the vacuum generators 26 to one another thereby making the extractor tool 44 more compact.
- the backflow port 60 may be embodied as an aperture 64 formed in the fitting 62 and a nozzle 66 , or other such fitting, secured thereto for connecting to the pneumatic source 22 . In one embodiment, the aperture 64 slopes downwardly through the fitting 62 , as shown in FIG. 3 .
- the vacuum generators 26 and fitting 62 are possible.
- a single vacuum generator 26 may be used.
- the fitting 62 having the port 60 formed therein may be disposed above or below the vacuum generator 26 (or generators 26 ).
- the vacuum generators 26 and fitting 62 may form a continuous channel opening into the upper surface 54 of the extractor catcher 46 .
- the backflow port 60 may include a separate channel independently connected to the upper surface 54 .
- each extractor tool 44 includes a backflow port 60 .
- extractor tools 44 both with and without backflow ports 60 are used. Such embodiments may be practical where multiple types of fasteners are being handled but not all tend to adhere to the extractor catcher 46 .
- FIG. 5 illustrates a method for using a fastener delivery system 10 in accordance with an embodiment of the invention.
- the control system 16 receives a request for a specific fastener configuration and identifies, through the execution of control software within a computing device (not shown), which fastener storage tube 28 within the fastener storage device 14 contains the proper fastener.
- the control system activates the linear X-Y positioner 48 to position the unloading mechanism 12 in the proper X-Y position adjacent the fastener storage device 14 , and more specifically, to position the extractor catcher 92 adjacent the appropriate fastener storage tube 28 .
- block 84 includes activating the pneumatic source 22 to cause the vertical axis positioner 50 to force the extractor catcher 46 down against the seal 30 disposed around the fastener delivery tube 28 .
- block 86 is executed, activating the vacuum generator 26 to cause at least one of the fasteners within the fastener storage tube 28 to move upward against the extractor catcher 46 .
- the top fastener abuts the upper surface 54 of the extractor catcher 46 , a seal is at least partially formed therebetween and the remaining fasteners (if any) fall back down into the fastener storage tube 28 .
- Block 88 the control system 16 positions the unloading mechanism 12 over the delivery conduit 18 .
- Block 88 may therefore include activating the vertical axis positioner 50 to move the extractor tool 44 up and away from the fastener storage device 14 and activating the linear X-Y positioner 48 to position the unloading mechanism 12 in the appropriate X-Y position adjacent the delivery conduit 18 .
- the linear X-Y positioner 48 positions the extractor catcher 46 adjacent the appropriate chute 40 of the drop plate 38 .
- Block 90 may include causing the pneumatic source 22 to activate the vertical axis positioner 50 to force the extractor catcher 46 down against the drop plate 38 .
- the extractor catcher 46 and drop plate 38 may form an air tight seal at their contacting surfaces.
- Block 90 may be omitted and the fastener dropped upon deactivation of the vacuum generator 26 at block 92 .
- the vacuum generator 26 is deactivated and the fastener is allowed to drop into the first fastener delivery tube 34 . Accordingly, the fastener is transported through the first fastener delivery tube 34 by gravity.
- the control system 16 evaluates whether the fastener has fallen from the extractor catcher 45 . In one embodiment, this occurs as the fastener is transported through the first fastener delivery tube 34 by gravity and past the proximity sensor 42 into the second fastener delivery tube 36 . If the fastener is sensed, then the method proceeds to block 96 .
- block 94 may include evaluating the output of a sensor capable of sensing the fastener positioned on the drop plate 38 , within the extractor catcher 46 , or at another point along the path of the fastener.
- the control system 16 activates the pneumatic source 22 to provide pressurized air through the second fastener delivery tube 36 to deliver the fastener to a work station.
- block 98 is executed.
- the back flow port 60 is activated, permitting air to flow through the backflow port 60 for one or more short bursts (or continuously). Bursts approximately one second in length have been shown to be effective to dislodge some fasteners.
- the air flowing through the backflow port may have any pressure effective to dislodge the fastener. Shop air at 90 psi or reduced to pressures from 60 to 80 psi has been shown to be effective.
- block 94 may be reexecuted to evaluate whether the fastener has dislodged from the extractor catcher 46 .
- Blocks 94 and 98 may be executed repeatedly until release of the fastener has been sensed at block 94 or a specific number of iterations have occurred. After the fastener is sensed at block 94 , the delivery conduit may be pressurized at block 96 to deliver the fastener to the work station. The method may then return to block 80 and be repeated, or the method may terminate.
- a block 100 may be executed before block 94 .
- Block 100 may include waiting for a period of time before evaluating whether the fastener has been released from the extractor catcher 46 .
- the amount of time may approximate the expected amount of time for a fastener to fall through the first fastener delivery tube 34 from the extractor catcher 46 to a point near the proximity sensor 50 .
- the step of releasing air through the backflow port 60 at block 98 may be executed for each iteration of the method, rather than only in instances where a fastener fails to fall due to gravitational forces.
- blocks 96 and 98 may be combined.
- pressurized air released from the backflow port 60 may serve both to dislodge fasteners from the upper surface 52 and to force the fastener along the first fastener delivery tube 34 , the second fastener delivery tube 36 , or both.
- Embodiments of the present invention may provide significant advantages over the prior art. For example, by sensing the passing of a fastener into the second fastener delivery tube, embodiments of the invention ensure that those fasteners which adhere within the extractor catcher are promptly detected so that appropriate action may be taken. Further, embodiments of the invention provide a backflow port which allow a fast, efficient, and cost effective means of dislodging fasteners which adhere within the extractor catcher. Thus, embodiments of the invention advantageously enable consistent release of fasteners and other components from a suction head of an automated fastener delivery system, thereby improving the efficiency and reducing costs of the manufacturing operation.
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Abstract
Fastener clearing systems and methods for a fastener delivery system are provided. In one embodiment, a system includes an extractor tool having one or more vacuum generators in fluid communication with a catcher for retaining fasteners during transport. The vacuum generators are selectively activated to draw fasteners into the catcher. A backflow port is formed in the extractor tool and introduces pressurized air into the catcher to dislodge fasteners that adhere to the catcher after the vacuum generators have been deactivated. The backflow port may be formed in a fitting positioned between vacuum generators and securing the vacuum generators to one another. The vacuum generators and fitting may define a common fluid channel opening into a fastener seat adapted to receive a portion of a fastener.
Description
- This invention relates generally to systems and methods for automated delivery of fasteners and, more specifically, to pneumatic fastener delivery systems.
- Automated fastener delivery systems in aeronautical applications should provide consistent operation. A typical aircraft will include thousands of fasteners, which must be installed quickly and cost-effectively. However, tools used to handle the fasteners may become fouled by contaminants, oils, or coatings that are carried by the fasteners. As a result, fasteners may adhere to tooling rather than releasing predictably. Lodged fasteners prevent consistent delivery of fasteners and cause delay when they must be removed by hand.
- Fastener handling tooling using suction heads to pick up or move fasteners is particularly vulnerable to this problem. A typical suction head creates a vacuum that draws the fastener into the suction head and retains the fastener. The suction head may then be moved to another location where the vacuum is deactivated and the fastener is allowed to fall under the force of gravity. The simplicity of operation and minimal moving parts of suction heads make them very cost effective. However, when the suction head is fouled by oils or other contaminants, a fastener may remain within the grip of the suction head after the vacuum is deactivated. Accordingly, although suction heads are an effective material handling tool, there is room for improvement.
- The present invention is directed to methods and apparatus for automated delivery of fasteners to an installation tool. Embodiments of the invention enable consistent release of fasteners and other components from a suction head of fastener handling tooling in an automated fastener delivery system.
- In one embodiment, an apparatus includes one or more fastener storage devices and an unloading mechanism in communication with the fastener storage device. The unloading mechanism includes a fastener seat having a fluid channel coupled thereto. A pneumatic control system regulates air flow between a pressurized air source and the fluid channel. The control system generates both overpressure and vacuum within the fluid channel. Vacuum may be generated by pneumatic vacuum generators in fluid communication with the fluid channel. Overpressure may be generated by releasing pressurized air into the fluid channel through a backflow port. In one embodiment, the backflow port is formed in a fitting securing first and second vacuum generators to one another.
- In operation, a pneumatic control system generates a vacuum within the fluid channel to draw at least one fastener from the fastener storage device into the fastener seat. The unloading mechanism is then moved to the delivery conduit. The control system then generates overpressure within the fluid channel to expel the fastener into the delivery conduit. In some embodiments, the vacuum is first deactivated and the fastener is allowed to fall into the delivery conduit. If the fastener fails to fall, then overpressure is generated within the fluid channel to expel the fastener. Whether the fastener falls may be determined by a proximity sensor secured on or near the delivery conduit.
- Embodiments of the present invention are described in detail below with reference to the following drawings.
-
FIG. 1 is a perspective view of a portable fastener delivery system suitable for use with a fastener clearing system, in accordance with an embodiment of the present invention; -
FIG. 2 is a perspective view of a delivery conduit, in accordance with an embodiment of the present invention; -
FIG. 3 is a perspective view of an extractor mechanism, in accordance with an embodiment of the present invention; -
FIG. 4 is a side view of an extractor catcher, in accordance with an embodiment of the present invention; and -
FIG. 5 is a process flow diagram of a method for using a fastener clearing system, in accordance with an embodiment of the present invention. - The present invention relates to systems and methods for automated delivery of fasteners to a fastener installation tool, and more specifically, to improved fastener clearing systems and methods. The present invention is suitable for use in fastener delivery systems, including the type generally disclosed, for example, in U.S. Pat. No. 6,688,489 issued to Daniel D. Bloch et al., which is incorporated herein by reference. Many specific details of certain embodiments of the invention are set forth in the following description and in
FIGS. 1 through 5 to provide a thorough understanding of such embodiments. One skilled in the art, however, will understand that the present invention may have additional embodiments, or that the present invention may be practiced without one or more of the details described in the following description. - Referring to
FIG. 1 , afastener delivery system 10 generally includes anunloading mechanism 12 in communication with afastener storage device 14, wherein acontrol system 16 causes theunloading mechanism 12 to remove a fastener having a specific configuration from thefastener storage device 14 and transport the fastener to adelivery conduit 18, wherein the fastener is delivered to a work station. As shown, thefastener delivery system 10 may be disposed within a portable platform, such as amobile cart 20, so that a variety of fasteners may be delivered to a plurality of work stations located throughout a manufacturing facility. - The
fastener delivery system 10 generally removes and delivers fasteners using apneumatic source 22. In one particular embodiment, thepneumatic source 22 is shop air at 90 psi (pounds per square inch). Thepneumatic source 22 may be activated by thecontrol system 16 and is in communication with both theunloading mechanism 12 and the delivery conduit 18 throughflexible tubing 24. The fittings that connect thepneumatic source 22 and theflexible tubing 24 are not shown for clarity. Thepneumatic source 22 activates one or a plurality ofvacuum generators 26 to remove a fastener from thefastener storage device 14 and secure the fastener within theunloading mechanism 12. Thefastener storage device 14 may include a plurality oftubes 28. Thetubes 28 may bearseals 30 for engaging theunloading mechanism 12. Once the fastener is secured within theunloading mechanism 12, the control system positions theunloading mechanism 12 adjacent thedelivery conduit 18, wherein thevacuum generators 26 are deactivated and the fastener is transported through thedelivery conduit 18 by gravity and by pressurized air from thepneumatic source 22. - Referring to
FIG. 2 , thedelivery conduit 18 further comprises adrop station 32 in communication with a firstfastener delivery tube 34 and a secondfastener delivery tube 36. As shown, thedrop station 32 further comprises a plurality ofdrop plates 38 that definechutes 40, through which the fasteners are dropped as previously described. In one particular embodiment, thechutes 40 are tapered, although a variety of shapes may be employed to effectuate transport of the fastener through thedelivery conduit 18. The plurality ofdrop plates 38 are employed to facilitate rapid interchangeability for a variety of fastener configurations. Alternately, a single drop plate may be employed rather than the plurality ofdrop plates 38. - As further shown in
FIG. 2 , the firstfastener delivery tube 34 extends from thedrop station 32 and is in communication with the secondfastener delivery tube 36. Generally, a fastener is transported through the firstfastener delivery tube 34 by gravity until the fastener passes beyond aproximity sensor 42. When theproximity sensor 42 detects the presence of a fastener, theproximity sensor 42 notifies thecontrol system 16, and thecontrol system 16 then activates the pneumatic source 22 (FIG. 1 ). Accordingly, thepneumatic source 22 provides pressurized air through the secondfastener delivery tube 36 to deliver the fastener to the work station. The workstation may include an end effector suitable for installing the fastener. - The first
fastener delivery tube 34 may be rigid in order to facilitate efficient transport of the fastener by gravity. Accordingly, in one particular embodiment, the firstfastener delivery tube 34 is fabricated from aluminum tube stock or other rigid material commonly known in the art. The secondfastener delivery tube 36 may be flexible so that the fastener may be delivered to a plurality of work stations throughout a manufacturing facility. Accordingly, the length of the secondfastener delivery tube 36 may be varied to accommodate the required distance from the portablefastener delivery system 10 to the work station. The amount of time that thepneumatic source 22 provides pressurized air through the secondfastener delivery tube 36 is a function of the length of the delivery tube and the fastener configuration being delivered, and therefore, the amount of time thatpneumatic source 22 is activated must be adjusted according to the length of the secondfastener delivery tube 36. - Additionally, the inner diameter of the second
fastener delivery tube 36 should be sized appropriately to prevent tumbling of the fastener along the length thereof, which is generally a function of the overall size of the fastener. Generally, the inner diameter of the secondfastener delivery tube 36 may desirably be slightly larger than the diameter of the fastener head yet smaller than the overall length of the fastener to prevent tumbling. Further, the secondfastener delivery tube 36 may be fabricated from relatively soft and flexible plastic such as nylon with a relatively smooth inner surface to minimize friction between the fastener and the inner wall of the secondfastener delivery tube 36. - Referring to
FIG. 3 , theunloading mechanism 12 generally comprises anextractor tool 44 having anextractor catcher 46 attached thereto. As further shown, in this embodiment, thevacuum generators 26 are disposed at an upper end of theextractor tool 44 and theextractor catcher 46 is disposed at a lower end of theextractor tool 44. - Although two (2)
extractor tools 44, each having two (2)vacuum generators 26, are illustrated herein, the portablefastener delivery system 10 according to the present invention may comprise any number ofextractor tools 44 andvacuum generators 26 to remove fasteners in accordance with specific operating requirements. Therefore, the illustrated embodiment which uses two (2)extractor tools 44 with two (2)vacuum generators 26 each should not be construed as limiting the scope of the present invention. - Generally, the
unloading mechanism 12 is positioned adjacent thefastener storage device 14 using a linearX-Y positioner 48 that is activated by the control system 16 (FIG. 1 ). More specifically, the linearX-Y positioner 48 positions anextractor catcher 46 of the unloading mechanism 12 (FIG. 3 ) adjacent the appropriatefastener storage tube 28 that contains the requested fastener. Accordingly, the X and Y position of eachfastener storage tube 28 is stored within thecontrol system 16 as described in greater detail below. Additionally, theextractor tool 44, along with theextractor catcher 46 attached thereto, may be translated in the vertical direction with avertical axis positioner 50 as shown. Theextractor catcher 46 is translated in the vertical direction in order to engage theextractor catcher 46 with thefastener storage tube 28 for removal of the requested fastener as described in further detail below. Moreover, thevertical axis positioner 50 may be pneumatically controlled and is therefore activated by thepneumatic source 22. - In operation, the
control system 16 activates the linearX-Y positioner 48 to position theunloading mechanism 12 adjacent thefastener storage device 14, and more specifically, to position anextractor catcher 46 adjacent the appropriatefastener storage tube 28. Once theproper extractor catcher 46 is positioned adjacent the appropriatefastener storage tube 28, thevertical axis positioner 50 moves theextractor tool 44 in the vertical direction until theextractor catcher 46 abuts theseal 30. - Referring to
FIGS. 3 and 4 , once theextractor catcher 46 is positioned against theseal 30 of the appropriatefastener storage tube 28, the pneumatic source 22 (not shown) then activates thevacuum generators 26, and as a result, one or more of thefasteners 52 within thefastener storage tube 28 move up against theextractor catcher 46. Once the head of atop fastener 52 abuts theextractor catcher 46 as shown, a seal may be created at the interface between thetop fastener 52 and theextractor catcher 46, thereby causing the remainingfasteners 52 to drop back into thefastener storage tube 28. As a result, theunloading mechanism 12 removes thetop fastener 52 from thefastener storage device 14 without the need for a separate fastener escapement mechanism. - As shown in
FIG. 4 , thefastener 52 abuts anupper surface 54 of theextractor catcher 46, and may create a sealed (or at least partially sealed) connection therebetween. In operation, the at least partially sealed connection causes the remaining fasteners to drop back into the fastener storage tube. As further shown, theextractor catcher 46 also comprises a taperedinner surface 56 to further facilitate ease of removal of thefastener 52 from thefastener storage device 14. Theupper surface 54 of theextractor catcher 46 may be modified to accommodate various types of fastener heads. Achannel 58 opens into theupper surface 54 of theextractor catcher 46 and is in fluid communication with the vacuum ports of thevacuum generators 26. - In some applications and conditions, the
fastener 52 may tend to adhere to thesurface 54. Adhesion may be caused, for example, by contaminants such as oil or dust within theextractor catcher 46. Adhesion may also result from coatings applied to afastener 52, such as a cetyl alcohol coating applied to prevent galvanic corrosion at interfaces between dissimilar metals. Where adhesion occurs, gravity may be insufficient to dislodge thefastener 52 from theextractor catcher 46. - As further shown in
FIG. 3 , theextractor tool 44 may include abackflow port 60 fluidly coupled to theupper surface 54 of theextractor catcher 46. Theblackflow port 60 may be coupled to a source of pressurized gas. For example, in one particular embodiment, one of theflexible tubes 24 may connect thebackflow port 60 to thepneumatic source 22. When a fastener lodges in theextractor catcher 46, pressurized air may be released through thebackflow port 60 to remove the fastener. In some embodiments, pressurized air is automatically and systematically released to ensure release of eachfastener 52 each time the vacuum is released to release thefastener 52 from theextractor catcher 46. Alternately, in other embodiments, pressurized air is released through thebackflow port 60 only in instances where thefastener 52 fails to fall from theextractor catcher 46. In either case, thecontrol system 16 typically regulates the release of air through thebackflow port 60. - In the illustrated embodiment, the
backflow port 60 is formed in a fitting 62 (FIG. 3 ) which secures the twovacuum generators 26 to one another. Forming theport 60 in the fitting 62 eliminates the need for separate parts for theport 60 and for securing thevacuum generators 26 to one another thereby making theextractor tool 44 more compact. Thebackflow port 60 may be embodied as anaperture 64 formed in the fitting 62 and anozzle 66, or other such fitting, secured thereto for connecting to thepneumatic source 22. In one embodiment, theaperture 64 slopes downwardly through the fitting 62, as shown inFIG. 3 . - Various arrangements of the
vacuum generators 26 and fitting 62 are possible. For example, asingle vacuum generator 26 may be used. The fitting 62 having theport 60 formed therein may be disposed above or below the vacuum generator 26 (or generators 26). Thevacuum generators 26 and fitting 62 may form a continuous channel opening into theupper surface 54 of theextractor catcher 46. Alternatively, thebackflow port 60 may include a separate channel independently connected to theupper surface 54. - In some embodiments, each
extractor tool 44 includes abackflow port 60. In others, such as the illustrated embodiment,extractor tools 44 both with and withoutbackflow ports 60 are used. Such embodiments may be practical where multiple types of fasteners are being handled but not all tend to adhere to theextractor catcher 46. -
FIG. 5 illustrates a method for using afastener delivery system 10 in accordance with an embodiment of the invention. Atblock 80, thecontrol system 16 receives a request for a specific fastener configuration and identifies, through the execution of control software within a computing device (not shown), whichfastener storage tube 28 within thefastener storage device 14 contains the proper fastener. Atblock 82, the control system activates the linearX-Y positioner 48 to position theunloading mechanism 12 in the proper X-Y position adjacent thefastener storage device 14, and more specifically, to position theextractor catcher 92 adjacent the appropriatefastener storage tube 28. - Once the
extractor tool 44 is properly positioned, block 84 includes activating thepneumatic source 22 to cause thevertical axis positioner 50 to force theextractor catcher 46 down against theseal 30 disposed around thefastener delivery tube 28. When theextractor catcher 46, or other sealing structure such as theshroud 94 disclosed in U.S. Pat. No. 6,688,489, abuts theseal 30, block 86 is executed, activating thevacuum generator 26 to cause at least one of the fasteners within thefastener storage tube 28 to move upward against theextractor catcher 46. When the top fastener abuts theupper surface 54 of theextractor catcher 46, a seal is at least partially formed therebetween and the remaining fasteners (if any) fall back down into thefastener storage tube 28. - In
block 88, thecontrol system 16 positions theunloading mechanism 12 over thedelivery conduit 18.Block 88 may therefore include activating thevertical axis positioner 50 to move theextractor tool 44 up and away from thefastener storage device 14 and activating the linearX-Y positioner 48 to position theunloading mechanism 12 in the appropriate X-Y position adjacent thedelivery conduit 18. More specifically, the linearX-Y positioner 48 positions theextractor catcher 46 adjacent theappropriate chute 40 of thedrop plate 38.Block 90 may include causing thepneumatic source 22 to activate thevertical axis positioner 50 to force theextractor catcher 46 down against thedrop plate 38. Theextractor catcher 46 and dropplate 38 may form an air tight seal at their contacting surfaces. Alternatively,Block 90 may be omitted and the fastener dropped upon deactivation of thevacuum generator 26 atblock 92. - At
block 92, thevacuum generator 26 is deactivated and the fastener is allowed to drop into the firstfastener delivery tube 34. Accordingly, the fastener is transported through the firstfastener delivery tube 34 by gravity. Atblock 94, thecontrol system 16 evaluates whether the fastener has fallen from the extractor catcher 45. In one embodiment, this occurs as the fastener is transported through the firstfastener delivery tube 34 by gravity and past theproximity sensor 42 into the secondfastener delivery tube 36. If the fastener is sensed, then the method proceeds to block 96. In other embodiments, block 94 may include evaluating the output of a sensor capable of sensing the fastener positioned on thedrop plate 38, within theextractor catcher 46, or at another point along the path of the fastener. Atblock 96, thecontrol system 16 activates thepneumatic source 22 to provide pressurized air through the secondfastener delivery tube 36 to deliver the fastener to a work station. - If the fastener is not sensed, then block 98 is executed. At
block 98 theback flow port 60 is activated, permitting air to flow through thebackflow port 60 for one or more short bursts (or continuously). Bursts approximately one second in length have been shown to be effective to dislodge some fasteners. The air flowing through the backflow port may have any pressure effective to dislodge the fastener. Shop air at 90 psi or reduced to pressures from 60 to 80 psi has been shown to be effective. After releasing a burst of air (or continuous flow of air) through thebackflow port 60, block 94 may be reexecuted to evaluate whether the fastener has dislodged from theextractor catcher 46.Blocks block 94 or a specific number of iterations have occurred. After the fastener is sensed atblock 94, the delivery conduit may be pressurized atblock 96 to deliver the fastener to the work station. The method may then return to block 80 and be repeated, or the method may terminate. - In some embodiments, a
block 100 may be executed beforeblock 94.Block 100 may include waiting for a period of time before evaluating whether the fastener has been released from theextractor catcher 46. The amount of time may approximate the expected amount of time for a fastener to fall through the firstfastener delivery tube 34 from theextractor catcher 46 to a point near theproximity sensor 50. - Various alternative embodiments of the method of
FIG. 5 are possible. In some embodiments, for example, the step of releasing air through thebackflow port 60 atblock 98 may be executed for each iteration of the method, rather than only in instances where a fastener fails to fall due to gravitational forces. In other embodiments, blocks 96 and 98 may be combined. In such embodiments, pressurized air released from thebackflow port 60 may serve both to dislodge fasteners from theupper surface 52 and to force the fastener along the firstfastener delivery tube 34, the secondfastener delivery tube 36, or both. - Embodiments of the present invention may provide significant advantages over the prior art. For example, by sensing the passing of a fastener into the second fastener delivery tube, embodiments of the invention ensure that those fasteners which adhere within the extractor catcher are promptly detected so that appropriate action may be taken. Further, embodiments of the invention provide a backflow port which allow a fast, efficient, and cost effective means of dislodging fasteners which adhere within the extractor catcher. Thus, embodiments of the invention advantageously enable consistent release of fasteners and other components from a suction head of an automated fastener delivery system, thereby improving the efficiency and reducing costs of the manufacturing operation.
- While preferred and alternate embodiments of the invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of these preferred and alternate embodiments. Instead, the invention should be determined entirely by reference to the claims that follow.
Claims (18)
1. (canceled)
2. The system of claim 29 , further comprising a vacuum source for providing the vacuum.
3-7. (canceled)
8. The system of claim 23 , further comprising an end effector coupled to a distal end of the delivery conduit.
9. The system of claim 23 , further comprising a source of pressurized air operatively coupled to the control system.
10. The system of claim 23 , further comprising a proximity sensor proximate the delivery conduit, the proximity sensor adapted to sense proximity of the component.
11-22. (canceled)
23. A component delivery system comprising:
a delivery conduit,
an unloading mechanism including an extractor catcher and a back flow port in fluid communication with an upper surface of the extractor catcher; and
a control system for causing the extractor catcher to drop a component into the conduit, and for commanding a supply of pressurized air to the back flow port to create an overpressure in the extractor catcher to ensure that the component is released from the unloading mechanism and falls into the delivery conduit.
24. The system of claim 23 , wherein the control system evaluates whether the component has passed into the delivery conduit and commands the overpressure if the component has not passed into the delivery conduit.
25. The system of claim 24 , wherein evaluating whether the component has passed into the delivery conduit includes detecting proximity of the component to the delivery conduit.
26. The system of claim 24 , wherein evaluating whether the component has passed into the delivery conduit includes detecting proximity of the component to the catcher.
27. The system of claim 24 , wherein evaluating whether the component has passed into the delivery conduit includes waiting for a delay period, and then evaluating passage of the component.
28. The system of claim 23 , wherein the overpressure is created automatically and systematically.
29. The system of claim 23 , further comprising a component storage device; and
wherein the control system commands a vacuum to be created within the extractor catcher to draw the component from the component storage device and into the extractor catcher.
30. The system of claim 29 , wherein the overpressure is created after both removing the vacuum and evaluating passage of the component.
31. The system of claim 29 , wherein the vacuum is also used to lift a component stack in the storage device, wherein a component is drawn off the stack by the extractor catcher, and wherein remaining components in the stack drop back after the drawn component enters and seals the catcher.
32. The system of claim 23 , wherein the extractor catcher includes a component seat adapted to engage the component, and wherein creating the overpressure includes releasing pressurized air between the component and the component seat.
33. The system of claim 23 , wherein the component is a fastener.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/236,594 US20120006845A1 (en) | 2005-10-18 | 2011-09-19 | Fastener clearing systems |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US11/253,209 US8046898B2 (en) | 2005-10-18 | 2005-10-18 | Fastener clearing systems and methods |
US13/236,594 US20120006845A1 (en) | 2005-10-18 | 2011-09-19 | Fastener clearing systems |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/253,209 Division US8046898B2 (en) | 2005-10-18 | 2005-10-18 | Fastener clearing systems and methods |
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US20120006845A1 true US20120006845A1 (en) | 2012-01-12 |
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ID=37758869
Family Applications (2)
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US11/253,209 Expired - Fee Related US8046898B2 (en) | 2005-10-18 | 2005-10-18 | Fastener clearing systems and methods |
US13/236,594 Abandoned US20120006845A1 (en) | 2005-10-18 | 2011-09-19 | Fastener clearing systems |
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US11/253,209 Expired - Fee Related US8046898B2 (en) | 2005-10-18 | 2005-10-18 | Fastener clearing systems and methods |
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US (2) | US8046898B2 (en) |
GB (1) | GB2445332B (en) |
WO (1) | WO2007047632A1 (en) |
Families Citing this family (11)
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DE102005041534A1 (en) * | 2005-08-31 | 2007-03-01 | Newfrey Llc, Newark | Supplying connecting elements, e.g. rivets or screws, to processing apparatus, involves two-stage conveyance via intermediate reservoir, allowing rapid, reliable interchange of different types of elements |
US8046898B2 (en) * | 2005-10-18 | 2011-11-01 | The Boeing Company | Fastener clearing systems and methods |
DE102010053220A1 (en) * | 2010-12-03 | 2012-06-06 | Brötje-Automation GmbH | Nietbereitstellungseinrichtung |
US8805575B1 (en) * | 2011-07-11 | 2014-08-12 | The Boeing Company | Methods and apparatus for delivering fasteners |
US20130263433A1 (en) * | 2012-03-26 | 2013-10-10 | Newfrey Llc | Automated Fastener Setting Tool |
US9278798B2 (en) | 2012-09-14 | 2016-03-08 | Honda Motor Co., Ltd. | High speed bolt dispenser |
US9266687B2 (en) * | 2013-06-24 | 2016-02-23 | The Boeing Company | Systems and methods for delivery of devices along a transport path |
CN104646987A (en) * | 2014-03-24 | 2015-05-27 | 广西梧州市平洲电子有限公司 | Rubber sleeve assembling device for radial inductor |
EP3056310A1 (en) * | 2015-02-16 | 2016-08-17 | BONINO S.p.A. con unico azionista | Device for the fast transport of objects |
CN105414943B (en) * | 2015-12-02 | 2018-06-01 | 深圳创维-Rgb电子有限公司 | The equipment and automated assembling system of automatic assembling screw |
US9937623B2 (en) | 2016-06-03 | 2018-04-10 | The Boeing Company | Methods and systems for kitting parts for manufacturing processes |
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Also Published As
Publication number | Publication date |
---|---|
GB2445332B (en) | 2010-10-20 |
GB0807327D0 (en) | 2008-05-28 |
GB2445332A (en) | 2008-07-02 |
WO2007047632A1 (en) | 2007-04-26 |
US20070084039A1 (en) | 2007-04-19 |
US8046898B2 (en) | 2011-11-01 |
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