WO2006096122A1

WO2006096122A1 - Modular system for an industrial robot

Info

Publication number: WO2006096122A1
Application number: PCT/SE2006/000303
Authority: WO
Inventors: Bernt BJÖRKMAN; Tommy Timhagen; Claes Johansson
Original assignee: Animex Plast Ab
Priority date: 2005-03-09
Filing date: 2006-03-08
Publication date: 2006-09-14
Also published as: SE0500540L; SE528350C2

Abstract

A system of modules for automatizing a sequence of processing operations in a production unit comprising an industrial robot (1) arranged on a stand adjacent to a plunger forming station and a number of functional modules (3) of which each one is arranged for performing at least one processing operation in the production unit, wherein said stand has a predetermined number of cells (5) for docking a functional module (3) into one of said cells (5), wherein said stand at its cell, respectively, has mechanical engagement members (7, 8) for precision engagement of a functional module (3) with the stand, the sequence of processing operations comprises a selection of functional modules (3) being docked into said cells (5) and wherein each cell (5) and each functional module (3) is provided with corresponding connectors (10) connecting all connection functions between a functional module (3) and the system in one single contacting function.

Description

MODULAR SYSTEM FOR AN INDUSTRIAL ROBOT

FIELD OF THE INVENTION

[001] The present invention relates to a system for automatization of a sequence of processing operations in a transfer line when an industrial robot is used for picking work pieces from a station where the work pieces are formed and being transported further for being processed at a number of stations, where different processing operations are being performed on the work pieces. Particularly, the invention relates to a device and a method for docking the stations to the industrial robot.

BACKGROUND OF THE INVENTION

[002] In the manufacturing industry there is an ever increasing need of a flexible automation. This applies to, e.g., production of uniform products made in smaller series, wherein the product is constructed around a base component, which is formed in, for example, a plunger moulding machine or in a mould in a metal foundry. The base component can be constituted by a chassis, a cover or the corresponding, where a number of processing operation have to be performed for the completion of the product.

[003] Such flexible automation for a rational handling of the subsequent operations is known through, e.g., an article with the title 'Offering robot" in the magazine: Packmarknaden, No. 17, 2002, pages 14 and 15. In said article multifunctional production modules are described, wherein the modules are built around 3-axles or 6- axles industrial robots. The concept includes a number of sector formed functional modules being located around the centrally stationed robot, so that the arm of the robot can perform different processing operations at different functional modules.

[004] By means of the concept, different production solutions can be adapted by means of standardized modules into one production unit and a high flexibility can be achieved, as a sequence of processing operations, that must be performed at the different functional modules relatively quickly can be re-tooled to another sequence of processing operations. This re-tooling is done by means of a replacement of one or more functional modules, whereby another production unit is created.

[005] Functional modules for around 30 different fields of applications are known. These can be combined optionally into a production unit to accomplish a wanted sequence of processing operations to be performed by the robot at the production unit. [006] The production unit is constructed around the industrial robot, winm ■» μιαv.cu un a stand. The stand is adapted to receive and to support the industrial robot and is at the same time the frame for a number of spaces being uniformly structured, in that it will be possible to dock the functional modules to the stand. Hence, said spaces have a design, which corresponds to the sector form of the functional modules.

[007] The standardization of the functional modules further includes that the body of the stand is provided with engagement members for precision engagement of a functional module with the stand. In that all dimensions hereby are known, a computing system, that co-ordinates and controls the work at the production unit, can integrate the movements of the industrial robot with the manipulations, which are necessary at the respective functional module.

[008] In the known system all connections, that must be performed between the stand and the respective functional module, are provided with quick couplings. Although, the described and known system considerably shortens the time for replacing from one production unit to another compared to conventional technology for providing a new and different sequence of processing operations at the new production unit, the handling of a number of connectors for communication, low voltage, high voltage and compressed air involves an unnecessary number of steps and taken together a plurality of manual efforts that must be performed. Particularly, as these efforts have to be performed for each functional module, both for disconnecting plugs of the functional modules that are removed from the production unit and for connecting desired functional modules at the replacement time is consumed for these connection actions. Furthermore, there are risks of mixing up one type of cable associated with one functional module with a corresponding type of cable associated with another functional module when the modules are to be collected into a production unit. One object of the present invention is to further shorten the time of replacement from one production unit into another.

[009] The patent US 6 598 279 discloses one example of a modular system for an automated process. A module of this system is arranged to replace a malfunctioning module with a corresponding module, wherein both modules are of the same kind and have the same function. To make it easier and faster to replace a module with another corresponding one a multi functional plug is used for connection of the module to the process. This multi functional connector can then be equipped with all connecting functions to connect the module to the process. The document does not mention a multi functional connector which constitutes a standard within the automated process in order to make it possible to install a module at a location free of choice within the process. DESCRIPTION OF THE INVENTION

[0010] According to one aspect of the invention a device with the characteristics of claim

1 is presented.

[0011] A further aspect of the invention is presented in the independent method claim.

[0012] Further embodiments of the invention are presented in the dependent claims.

[0013] The connection functions being referred to in the present invention are first of all: a data communication line, low voltage cables and a conduit for compressed air. The data communication between the robot and the functional module is controlled by e.g. a main computer of the system. By this, information can be conveyed to and from the functional module, e.g. for positioning an object. The cable for low voltage can, by example, provide 230 V one phase operating voltage for different operation and apparatus demands of the functional module.

[0014] As mentioned, the connections of the cables and conduits according to prior art systems have been performed by means of quick couplings, which implies that a plurality of cables and conduits with connectors must be provided at each docking cell, where these shall be handled manually one by one, separately, at docking a functional module to a cell. Additionally, different functional modules could have different sets of connection functions. According to the invention all connection functions are integrated to one connector for each cell, respectively, and a corresponding connector for each functional module. Thus, these multi functional connectors comprise both connections for communication, low voltage, high voltage and compressed air. A great advantage with the invention is that the coupling together of all connection functions between the functional module and the robot stand can be effected in one moment and with one manual operation per cell at docking a functional module to the cell. The docking time at replacement of the functional module in a cell is hereby reduced by use of the invention at the same time as the handling at docking is simplified.

[0015] One production unit is composed with an industrial robot in the centre. The robot is placed on a stand, which is also provided with a predetermined number of cells for the reception of and for being joint to a functional module for each cell, respectively. The cells have a similar and a uniform design in so far as to dimensions and shape of the cells being such that the dimension and shape of the functional modules are adapted to be freely exchangeable and possible to dock to any of the cells. [0016] By choosing functional modules for effecting a certain sequence ui _{μι uw}..uιy operations a flexible production unit is possible to erect. Functional modules for performing processing operations are available in a number of variants. Here, a number of available variants of functional modules are listed, where such a module is arranged to perform processing operations from the group of : laser marking, labeling, pallet loading, vibrator feeding, glueing, machining, deionization, blaze, granulation, weighing, surfacing, screw driving, tampo pressing, corona treatment, laser measureing, quality sorting, robot tooling, linear feeding, cardboard box raising, taping. The functional modules may also have as a function, that they should be equipped with a multiple switchboard or serve as a store. For certain processing operations a smaller manipulator can also be included in the functional module, wherein this manipulator can perform a plurality of different processing operations, e.g, when the industrial robot cannot itself in a timely manner effect all of the processing operations of all the functional modules included in the processing unit. The choice of functional modules thus forms a specific production unit, which kan be established in a short time.

[0017] A functional module is, as mentioned, docked into a cell and is mechanically coupled together with the cell by means of members for precision engagement. In the actual case, this is done by means of holes in the stand associated with the cell concerned and corresponding pins associated to the functional module or vice versa. On the very docking moment guides, described below, are used.

[0018] According to the aspect of the invention replacement or setting up a functional module within an optional cell of the production unit is accomplished in a quicker and more simple way, as all the types of functional modules being dependent of a connection to the production unit through a connection function, such as a control function, a power function (power supply), cooling function, compressed air function, etc. are equipped with a uniform and within the units of the production unit standardized connector, which connect all connection functions between a functional module and the system in one connecting function independent of which connection functions, that are present at the individual functional module.

DESCRIPTION OF THE DRAWINGS

[0019] Fig. 1 shows a production unit according to one aspect of the invention.

Fig. 2 shows from above 6 functional modules placed neighbouring each other. Fig. 3 schematically shows a functional module stripped from equipment, wmui uie module can contain for performing processing operations.

Fig. 4 is a perspective view of the front side of a multi functional connector for connection of the functional module to the production unit.

DESCRIPTION OF EMBODIMENTS

[0020] A number of embodiments of the device and for carrying out the method according to the invention will be described in the following supported by the enclosed drawings.

[0021] Fig. 1 shows a production unit according to one aspect of the invention, wherein an industrial robot 1 picks objects from a product forming station (not shown) for subsequent treatment of the objects in different processing operations in a number of functional modules 3 being arranged around the industrial robot 1. The product forming station can be represented by a plunger moulding machine for forming plastic products, for example, the basic members of products in the form of chassis, housings, etc. According to an other alternative a product forming station can be composed of a station, wherein metal structures are casted in a mould for use of said structure in the product being manufactured at the production unit. In the production unit according to fig. 1, wherein the functional modules 3 are arranged in a half circle, the product forming station occupies at least a part of the space along the half circle which is not filled by functional modules and which the industrial robot 1 can reach. In this description, for the sake of clarity, this product forming station is also called a system of modules.

[0022] The industrial robot 1 is controlled according to a central control program associated to the production unit and being arranged in connection with the industrial robot. By means of this control it is provided for the industrial robot to pick up a product (possibly several at the same time) from the product forming station, in order to, subsequently in turn cause the product (the products) to pass a number of processing operations at the different functional modules 3. In figure 1, only one processing operation at a functional module is illustrated through an equipment, which in general is symbolized by a processing station 2. The processing operations, which shall be performed at the respective functional module is dependent of the product and is not any further discussed here, as this belongs to prior art technology. The sequence of processing operations, which shall be performed in connection with the preparation of the product respectively forms the basis of the selection of functional modules 3. O

[0023] The functional modules 3 are in the example arranged in a semi ^m-ic αiuunu me industrial robot 1 to give the industrial robot access to all functional modules. For that reason, the functional modules are substantially designed as sectors of a circle, in the shown case, an example where 6 functional modules form a semi circle. It is fully conceivable to increase the number of modules so that they will form a complete circle or a bigger part of a circle. Hence, at a production unit, the functional modules 3, with all of them being of the same size, can be arranged in a number up to 12.

[0024] The industrial robot 1 is placed on a stand (not shown) comprising a plate 4. This plate 4 is hereby, according to the example, arranged to receive 6 functional modules, which can be engaged to said stand in a location reserved for each one of the functional modules, here called a cell 5. The functional modules 3 of the system are arranged for being docked to the stand by being mechanically engaged to the plate 4. The mechanical part of the docking can be arranged to be accomplished in different ways. Thus, it is shown in figures 1, 2 and 3 that a sector formed bottom plate 6 of the functional modules 3 is provided with locking pins 7 at the most narrow part of the bottom plate 6. In correspondence with this the plate 4 of the stand is provided with locking members for the locking pins 7 in the form of holes 8. The holes 8 are at each cell respectively arranged to grasp the locking pins 7 and lock the docking functional module 3. The positions for the holes 8 and the locking pins 7 respectively are precision performed and their positions are known, whereby the program controlling the production unit will be completely updated with all necessary data regarding positions for a functional module 3 as soon as it has become connected to the system, i.e., when the control program can communicate with the functional module 3. It is, of course, possible to design the precision engagement and to lock the functional modules in another way. To provide the functional modules with holes 8 and the plate 4 of the stand with locking pins 7 is such an alternative, but other possibilities also exist. The docking is arranged in such a way that a guide 9a and a guide pin 9b together direct the functional module 3 into the correct position, whereby the functional module can be lowered to the plate 4, whereby the locking pins 7 and the holes 8 lock the functional module 3 and the stand to each other.

[0025] At docking a functional module 3 to the plate 4 in one of the cells 5 (the cell 5 is only constituted by a reserved space and does not comprise any surrounding walls), the docking is facilitated owing to a tapering cut-in portion guiding the functional module 3 to an exact position by means of a guiding pin 9b on the plate 4. For the sake of clarity only solitary guides 9a and guiding pins 9b are indicated in the figures. They can of course be found with their equivalences in each cell and functional module. [0026] A functional module 3 can be equipped with all kind of outfit for eπecuπg processing operations in the production unit. This outfit can be represented by motors, grinding sets, burring tools, polishing tools, gluing devices, packaging devices, assembling tools, etc. In certain circumstances a smaller manipulator can perform a number of partial functions at a functional module, wherein at the production unit the industrial robot 1 must be unloaded to manage to get all partial functions done.

[0027] To be able to deliver power and control voltages to equipment at the functional module 3 and to get a possibility to control the equipment, when it is connected to the system, the equipment must become connected to the production unit by way of conduits. This is performed through providing the functional modules 3 with connection functions, which are coupled to corresponding connection function located on the stand at the cell 5 respectively for docking. According to the invention this is effected in one operation only at the docking of a functional module into a cell of the production unit by means of one multi function connector being arranged at the cell respectively and one corresponding connector at each functional module 3.

[0028] Such a connector 10 provides the total need of connections between the functional module 3 and the stand with its cell 5. Fig. 4 depicts the connector 10 with its multi function through a picture, which shows the contacts of the connector 10 from the front. Fig. 4 reproduces one of the connectors 10, as it is arranged at a cable end for a functional module 3. In the figure the contact sockets integrated in the connector 10 are reproduced by means of its function, wherein the contact respectively is numbered accordingly: 10a: connection for power

10b: connection for operation voltage

10c: socket for voltage supply via a data network

1Od: contact socket for signal communicaton via a data bus

1Oe: connection for serial data communication 1Of: connection for compressed air (for operating pneumatic units of a functional module).

Thus, the connector 10 constitutes a contact member, which in itself includes all the connection functions present at functional modules 3 structured to be received by the cells 5 of the system.

[0029]The power supply of the connection 10a includes both 230 V single phase and 400

V three-phase. The other connections are used according to the following: o

10b: Operation voltage used for a safety switch on the modules, e.g. at uμcmny υι α gate. This switch is interconnected with an auto stop function of the robot. 10c: Voltage feed to sensors and valves. The voltage feed is switched off at auto stop. 1Od: Data bus communication for sensors and valves. 1Oe: This connection is used for communication between a control system and an external computer. 1Of: Used, for example, for strokes in a working cylinder.

[0030] The functional module, respectively, is provided with a cable for connection to the production unit by means of the single connector 10, as is shown in fig. 1. In this figure, it is also shown that said connector 10 is coupled together with the corresponding receiving connector being arranged on the walls of a jack panel 11 of the robot stand and thus located on top of the plate 4. In the example it is shown that the jack panel 11 has four sides and in the shown embodiment provided with 2 receiving connectors on three of the walls of the jack panel. The jack panel can, of course, be of another shape and be arranged for the reception of more connectors 10.

[0031] As the mentioned connector 10 functions as a standard between the functional modules 3 and the cells 5 of the system, the same connector 10 can be connected in one hand grip independently of which functional module, that is connected to the production unit, i.e. which task to be performed at the functional module 3. By this, the handling is simplified and set-up times for replacement of functional modules at rearranging a production unit is shortened.

[0032] Although the present invention has been described in connection with specific embodiments, the invention shall not be limited to the, or those, specific forms, of which they have been illustrated in this description. As a matter of fact, the scope of the present invention is only limited by the attached claims. In the claims, such terms as comprising and including do not exclude the presence of other elements or steps. Further, although they are not individually listed, a plurality of devices, elements or method steps can be implemented by, e. g., one single unit. Furthermore. Although, individual features can be included in different claims, these can possibly advantageously be combined and the inclusion in different claims does not imply that a combination of features is not proper and/or advantageous. Furthermore, singular references do not exclude a plurality. Thus, references to "one", "first", "second", etc. do not prevent that a plurality occurs, if this is not explicitly emphasized. References in claims are only added as clarifying examples and shall not be interpreted as limiting the scope of the claims in any way.

Claims

1. A system of modules for automatizing a sequence of processing operations in a production unit, comprising: - an industrial robot (1) arranged on a stand adjacent to a product forming station,

- a number of functional modules (3), each one of them arranged for performing at least one processing operation in the production unit,

- said stand has a predetermined number of cells (5) with a uniform design for docking a functional module (3) into one of said cells (5), - said stand has at each cell, respectively, mechanical engagement members (7, 8) for a precision engagement of a functional module (3) to the stand,

- the functional modules are freely exchangeable and possible to dock into any one of the cells (5), characterized in that:

- the sequence of processing operations includes a selection of functional modules (3) being docked into said cells (5), and

- each cell (5) and each functional module (3) is equipped with corresponding connectors (10) connecting all connection function between a functional module (3) and a cell of the system in one single connecting function, and

- the connector (10) serves as a standard in the system, whereby a functional module (3) can be docked into a cell (5), free of choice, and become connected to the production unit by means the connector (10) in one single hand grip and independent of which functional module (3) being connected.

2. The system according to claim 1, wherein the connector (10) is composed by a contacting member, in itself comprising connections for at least the connection functions:

- connection for power (10a),

- connection for operation voltage (10b),

- connection for voltage supply via a data network (10c), - connection for signal communicaton via a data bus (1Od),

- connection for serial data communication (1Oe),

- connection for compressed air (1Of).

3. The system according to claim 1, wherein the connector (10) is composed of a contacting member, in itself including all connection functions present at the functional modules (3) arranged to be received by the cells (5) of the system.

4. The system according to any of the preceding claims, wherein the v.uιmcv.ι.uι

ui a functional module (3) at docking into a cell (5) is connected to a corresponding connector (10) being a part of the cell (5) and mounted on a jack panel arranged at the stand of the industrial robot (1).

5. The system according to claim 1, wherein the mechanical engagement members (7, 8) is composed of locking pins (7) and corresponding holes (8) at functional modules and stand.

6. A method for connection of functional modules of a system for automatizing a sequence of processing operations in a production unit, wherein:

- an industrial robot (1) is arranged on a stand adjacent to a product forming station,

- a number of functional modules (3) are each arranged for performing at least one processing operation in the production unit,

- said stand is arranged to have a predetermined number of uniform cells (5) for docking a functional module (3) into one of said cells (5),

- said stand has for the cell, respectively, mechanical engagement members (7, 8) for precision engagement of a functional module (3) with the stand, - the functional modules (3) are designed to be freely exchangeable and possible to dock into any one of the cells (5), characterized in that the method comprises the steps of:

- a number of specific functional modules (3) are selected to perform a sequence of processing operations in the production unit, - each selected functional module (3) is docked into a cell (5), and

- all connection functions of a functional module (3), which is docked into a cell (5), are connected to the production unit by means of a contacting function which is connected through one single manual operation, and

- wherein said contacting function is included in one connector (10) designed as a standard of the system, whereby a functional module (3) is docked into a cell (5) free of choice and being connected to the production unit by means of the connector (10) in one hand grip independent of which functional module (3) being connected.