U.S. patent application number 14/619949 was filed with the patent office on 2015-08-27 for process of positioning automotive components.
This patent application is currently assigned to METALSA S.A. DE C.V.. The applicant listed for this patent is METALSA S.A. DE C.V.. Invention is credited to Marvin Lewis Adams, Jason Belcher, Juan Villarreal Garcia.
Application Number | 20150239068 14/619949 |
Document ID | / |
Family ID | 53881328 |
Filed Date | 2015-08-27 |
United States Patent
Application |
20150239068 |
Kind Code |
A1 |
Garcia; Juan Villarreal ; et
al. |
August 27, 2015 |
PROCESS OF POSITIONING AUTOMOTIVE COMPONENTS
Abstract
A process and system for measuring, positioning and welding a
bracket 30 to a mounting surface, such as a vehicle side rail 40,
to accomplish smooth and continuous bracket assembly. A bracket
positioning tool 20 on a robotic arm 10 allows brackets 30 to
adjust to minimize the gap between the bracket 30 and its intended
mounting surface. The bracket positioning tool 20 positions
brackets 30 near the surface, and allows brackets 30 to adjust for
a precise surface match. With input from a second measurement, a
welding robot 50 welds the bracket 30 to the surface with the gap
minimized while the bracket 30 is held in position. The measurement
system and bracket positioning with flexible tooling do not require
the bracket 30 to be forced with pressure against the mounting
surface. With robots, brackets can be consistently placed and
welded in precise locations on varying mounting surfaces.
Inventors: |
Garcia; Juan Villarreal;
(Saltillo, MX) ; Belcher; Jason; (Cecilia, KY)
; Adams; Marvin Lewis; (Elizabethtown, KY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
METALSA S.A. DE C.V. |
Apodaca |
|
MX |
|
|
Assignee: |
METALSA S.A. DE C.V.
Apodaca
MX
|
Family ID: |
53881328 |
Appl. No.: |
14/619949 |
Filed: |
February 11, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61944013 |
Feb 24, 2014 |
|
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Current U.S.
Class: |
228/102 |
Current CPC
Class: |
B23K 37/0452 20130101;
B23K 37/047 20130101; B23K 2101/006 20180801; B23K 37/0229
20130101; B25J 9/1679 20130101; Y10S 901/42 20130101; B23K 31/12
20130101; B23K 2101/28 20180801; B23K 31/02 20130101; B25J 15/0066
20130101; B25J 9/1697 20130101; B23K 2103/04 20180801 |
International
Class: |
B23K 31/12 20060101
B23K031/12; B23K 31/02 20060101 B23K031/02 |
Claims
1. A process of welding a bracket to a mounting surface including
using an adjustable tool on a moveable arm that allows the bracket
to adjust to minimize gap between the bracket and its intended
mounting surface, comprising the steps of: securing the bracket via
the moveable arm; measuring current position of the mounting
surface and current position where the bracket is to be placed;
positioning the bracket at a desired position adjacent to the
mounting surface based on measurements of the positions; minimizing
the gap between the bracket and the mounting surface through
positioning via the adjustable tool, measuring the position of the
bracket and providing positioning input to a welding robot to
precisely weld the bracket to the mounting surface, and welding the
bracket to the mounting surface using the welding robot with the
gap minimized while the bracket is held in the desired
position.
2. The process of claim 1 including a step of using vision sensors
to observe, detect, perceive or determine positioning of the
bracket, and positioning the bracket with a robot.
3. The process of claim 1 wherein surface match of the bracket to
the mounting surface does not require the bracket to be forced with
substantial pressure against the mounting surface, and the height
of the bracket relative to the mounting surface is adjusted by an
adjustable appendage on which the adjustable tool is mounted on a
distal end of the moveable arm based on input from measuring the
current position.
4. A method of manufacturing vehicle side rail with a bracket
welded on a portion of the side rail using a measuring system, a
bracket positioning tool and a welding robot, the method comprising
the steps of: securing the bracket with the bracket positioning
tool on an end of a moveable arm; moving the end of the moveable
arm toward the side rail; measuring current position of the side
rail and current position where the bracket is to be placed
positioning the bracket adjacent to the side rail; minimizing a gap
between the bracket and the side rail through adjustments via the
bracket positioning tool that allows the bracket to adjust;
measuring the gap and providing measurement input to the welding
robot, and welding the bracket to the side rail using the welding
robot with the gap minimized while the bracket is held precisely in
position throughout the welding.
5. The method of claim 4 further includes adjusting the bracket
linearly with an appendage located between the bracket positioning
tool and the end of the moveable arm, wherein the appendage adjusts
based on measurements of the side rail and the bracket.
6. The method of claim 4 further comprising a step of using vision
sensors to observe, detect, perceive or determine positioning of
the bracket.
7. The method of claim 4 wherein the welding robot is also mounted
on the moveable arm as a combination end adapted to operate on the
distal end of the moveable arm, and the welding robot moves
relative to the bracket positioning tool, which is stationary
during welding to hold the bracket in place.
8. A process of welding a bracket to a mounting surface including
using a robotic arm that allows the bracket to adjust to minimize
gap between the bracket and its intended mounting surface,
comprising the steps of: securing the bracket via the robotic arm;
measuring current position of the mounting surface and current
position where the bracket is to be placed; providing data of the
positions to the robotic arm; positioning the bracket at a desired
position via the robotic arm adjacent to the mounting surface based
on measurements of the positions with minimal the gap between the
bracket and the mounting surface, measuring the position of the
bracket and providing positioning input to a welding robot to
precisely weld the bracket to the mounting surface, and welding the
bracket to the mounting surface using the welding robot with the
gap minimized while the bracket is held in the desired
position.
9. The process of claim 8 including using vision sensors to
observe, detect, perceive or determine positioning of the bracket.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and all benefits of U.S.
Provisional Application 61/944,013, filed on Feb. 24, 2014,
entitled "Pivoting Tool for Positioning Automotive Components and
Method Thereof", which is incorporated herein by reference.
FIELD OF THE DISCLOSURE
[0002] This disclosure relates a bracket positioning process,
specifically, for measuring positions and placing an automotive
component, such as a bracket, in a desired position, with a
measurement system and a bracket positioning tool, such as a
pivoting tool, before welding the component to a vehicle chassis
frame, preferably using input from further measurements.
BACKGROUND
[0003] In large welding operations, such as those present in the
automotive industry, high flexibility operations are a significant
concern. Flexibility is pursued by creating tools and operations
that may be utilized for welding several different components and
by simplifying the equipment and devices to be more versatile and
less costly.
[0004] In a cell, the frame position varies with each bracket due
to the nature of the operation. The position of the frame and the
position where the bracket must be placed can vary with each frame
coming through the cell. Each entering frame does not arrive
exactly at the same spot of the cell. Variations of a few
millimeters are common, and such variations can adversely affect
the bracket positioning and the final assembled frame with a
mounted bracket.
[0005] Many tooling efforts have been developed for creating more
flexible welding operations regarding structural chassis frames,
specifically, for those components that are attached to the main
side rails, such as steel brackets. Welding operations usually
demand specialty tools. In the case of the brackets, it is common
practice to secure brackets in their desired position by using a
lineal pneumatic arm, which keeps the brackets at the desired
position by pressing the bracket into the component to which it
will be welded. This less flexible tool is a dedicated fixed unique
station that slides and then presses the bracket against the side
rail.
[0006] In high volume welding operations, such as those present in
the automotive industry, where several formed components proceed
into welding processes, it is common to find variations in the
geometry of materials according to specification tolerances. To
optimize the joining of components, the welding processes must
guarantee that a variation within formed components does not affect
the welding precision and therefore, it is common to make
adjustments in the tooling placement.
[0007] Tools designed to place a component, such as a bracket, into
a desired position by utilizing force, such as pneumatic force, are
usually oversized and expensive tools.
[0008] The present disclosure describes a positioning tool and its
corresponding method to guarantee that an automotive component,
such as a bracket, is placed within a desired position without the
need of utilizing oversized and costly specialty tooling.
SUMMARY AND OBJECTS OF THE DISCLOSURE
[0009] The present disclosure is directed to bracket placement and
welding processes. The measuring, component positioning and welding
allows for precise positioning and a minimal space gap between the
automotive components to be welded, such as a bracket with the
surface to where the component is to be welded, such as a vehicle
chassis frame side rail.
[0010] In the overall bracket positioning process, an adjustable
tool from the present disclosure is attached to a robotic arm,
wherein the robotic arm takes a bracket from a bracket pool. The
robotic arm is then automated to place the bracket in a specific
position on a vehicle side rail surface. A pivoting tool can
automatically pivotal to guarantee that the gap between the bracket
and the side rail is minimized.
[0011] The preferred process uses an initial measurement system
that as a first major step reads the exact position of the frame
and the position where the bracket must be placed when the frame
enters the working cell. The measurements from the measurement
system are the input for the bracket positioning step.
[0012] The measurement system reads the exact position of the frame
and then where the bracket will be placed and mounted. The bracket
positioning input can differ for each frame coming through the
cell.
[0013] Next, the tool receives the bracket positioning input from
the initial measurements, adjusts the bracket position based on the
initial measurements, uses software code for "offsetting robot
positions", and uses the measurement system to position the robot
that is holding brackets.
[0014] After the bracket position is optimized, a welding robot
approaches the gap between the bracket and the side rail and welds
both components together. In the third major step of welding the
bracket, a welding robot preferably receives input from the second
measurement of the gap and welds the bracket at the desired
position using the measurement input.
[0015] The present disclosure provides an adjustable tool
characterized by being able to be attached to a robotic arm,
wherein the tool has the ability to adjust and pivot and wherein
such adjustment guarantees that the surface gap caused by geometric
variations within tolerance, gets positioned wherein the welding
operation is optimized.
[0016] Even though the frame position varies with each bracket due
to the nature of the operation, the same spot can be determined
where each frame arrives at the cell. Variations are common due to
heating and forces on the mounting surface, for example, and such
variation affects the bracket positioning. Variations of just a
couple millimeters can be avoided with the measuring, bracket
positioning, and welding of the bracket, preferably based on
multiple measurements.
[0017] It is therefore an object of the present disclosure to
provide tools and a method that measures and minimizes the gap
between two components that are going to be welded together without
the need to utilize force to guarantee positioning of the
components. Measurement, bracket positioning and welding with an
adjustable robot accomplish a smooth and continuous bracket
assembly with precise and consistent bracket placement on varying
frames.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above-mentioned and other features of this disclosure
and the manner of obtaining them will become more apparent, and the
disclosure itself will be best understood by reference to the
following descriptions of tools and processes taken in conjunction
with the accompanying figures, which are given as non-limiting
examples only, in which:
[0019] FIG. 1 is a perspective view of an adjustable tool attached
to a robotic arm as described in the present disclosure;
[0020] FIG. 2 is a perspective view of the adjustable tool without
a bracket on a robotic arm;
[0021] FIG. 3 is a top view of the adjustable tool showing pivoting
of a bracket to adjust to surface changes that may be on the
surface to which the bracket may be welded;
[0022] FIG. 4 is a perspective view of the larger system with the
robotic arm placing a bracket adjacent to a side rail for welding;
and
[0023] FIG. 5 is a perspective view of a combination end with a
bracket loading pivoting tool, a measurement system, and a welding
robot.
[0024] The exemplifications set out herein illustrate embodiments
of the disclosure that are not to be construed as limiting the
scope of the disclosure in any manner. Additional features of the
present disclosure will become apparent to those skilled in the art
upon consideration of the following detailed description of
illustrative embodiments exemplifying the best mode of carrying out
the disclosure as presently perceived.
DETAILED DESCRIPTION
[0025] While the present disclosure may be susceptible to
embodiments in different forms, the figures show, and herein
describe in detail, embodiments with the understanding that the
present descriptions are to be considered exemplifications of the
principles of the disclosure and are not intended to be exhaustive
or to limit the disclosure to the details of construction and the
arrangements of components set forth in the following description
or shown in the figures.
[0026] After the frame, such as a side rail 40, gets to the cell, a
measurement system 44 mounted on either the robot or any part of
the cell reads the exact position of the frame and the position
where the bracket 30 must be placed. Even though the frame position
varies with each bracket due to the nature of the operation, the
same spot can be determined where each frame arrives at the cell.
The measurements from the measurement system 44 are the input for
the bracket positioning step.
[0027] Next, the tool receives the bracket positioning data from
the initial measurements, and the bracket positioning is adjusted
based on the initial measurements and uses software code for
"offsetting robot positions" and uses another measurement system to
position the robot that is holding brackets. The robot positions
the bracket 30 to adjust for slight variations of each frame in the
cell.
[0028] A bracket positioning tool 20, such as an adjustable
pivoting tool, can be used as part of a robotic system with a
moveable arm, such as a preferred robotic arm 10 that can move on
six axes. Unlike a bracket being forced against a mounting surface
for welding with pressure, the adjustable tool 20 ensures surface
match of the bracket 30 against a mounting surface without
significant force or loosening of a tool while allowing for slight
height variance, preferably adjusted by the initial measurements of
the measurement system 44. The adjustable tool 20 adjusts for
surface change and variations. Surface gap is avoided with specific
matching against varying mounting surfaces, which may vary with
heat distortion or other conditions.
[0029] As shown in FIG. 1, an adjustable tool 20 attached
mechanically to a robotic arm 10 grabs a component, such as a
bracket 30, and wherein the adjustable tool 20 allows the bracket
30 to move about or around a specific axis to minimize the surface
gap between the bracket 30 and the surface to which the bracket 30
is to be welded, such as a side rail 40. The adjustable tool 20
preferably pivots relative to an appendage 12 or base on the
robotic arm 10. In a preferred embodiment, the adjustable tool 20
is characterized by having vision or strength sensors 14 to
guarantee that the bracket 30 is positioned at a desired place. The
second measuring system 48 can be associated with the sensors 14,
such as a vision system, which provide input for the bracket
welding step. The second measurement of the bracket 30 can provide
input that is provided to a welding robot to weld exactly where the
bracket 30 is positioned.
[0030] As shown in FIG. 2, the adjustable tool 20 pivots around a
pivot pin 16 relative to the appendage 12. The appendage 12 is
preferably attached on a distal end of the robotic arm 10, and the
appendage 12 allows for precise movement of the bracket 30. The
appendage 12 can be adjustable to allow for height variations or
slight adjustments, such as by a height adjustor 22 that moves
linearly relative to the robotic arm 10. Various vision and
strength sensors 14 can observe, detect, perceive and/or determine
placement, force and location for adjustment based on preprogrammed
code controlling the placement of the bracket 30 relative to the
side rail 40 as an example.
[0031] FIG. 2 shows the adjustable tool 20 as the portion that
pivots around the pivot pin 16 in a detailed component. This
exemplary adjustable tool 20 has at least one grip 18 that grasps,
secures, clamps or otherwise holds the bracket 30 as it can be
retrieved from a bracket pool, positioned, held, and welded to a
side rail 40. Preferably, a grip 18 holds each side of the bracket
30, depending on the configuration of the bracket 30. The bracket
30 is released from the adjustable tool 20 after it is welded to
the side rail 40.
[0032] FIG. 3 shows how the bracket 30 can automatically pivot to
adjust to surface changes or variations that may be on the surface
of the side rail 40 to which the bracket 30 may be welded. The
bracket 30 can pivot about an axis of the pivot pin 16 to adjust as
needed, as would minimize the space or surface gap between the
bracket 30 and a side rail 40 to which it is intended to be
welded.
[0033] The adjustable tool design allows for the bracket 30 to
adapt to changes, ensuring surface match with the mounting surface
of the side rail 40 through adjustments and pivoting positioning
via the adjustable tool 20 without using substantial force against
the mounting surface or loosening of the tooling that allows for
height variations or other slight adjustments.
[0034] According to the present disclosure, the process of
positioning the bracket 30 at the desired position for welding
involves securing the bracket 30, such as taking a bracket 30 from
a bracket pool, measuring the exact position of the frame and
bracket placement location, positioning the bracket 30 adjacent to
the desired surface with a robotic arm 10 using the measurement
input, minimizing the space gap between the bracket 30 and the side
rail 40 through adjusted positioning via an adjustable tool 20,
preferably by using sensors 14 (i.e. vision and strength) for
another measurement. Then the bracket 30 is welded to the side rail
40 while the bracket 30 is held in the desired position. The
welding robot 50 preferably receives input from the second
measurement system 48 and precisely welds the bracket 30 at the
desired position on the frame. Throughout the step of welding, the
gap is minimized between bracket 30 and the mounting surface. The
precise measuring and smaller gap should use less welding
material.
[0035] In more detail, the process of placement before welding a
bracket 30 to a mounting surface includes the adjustable tool 20
securing and positioning the bracket 30 at a desired position close
to the mounting surface, minimizing the gap between the bracket 30
and the mounting surface via pivoting of the adjustable tool 20,
automated movement of the robotic arm 10, and possible adjustment
by an appendage 12 between the adjustable tool 20 and the end of
the robotic arm 10.
[0036] FIG. 4 shows positioning the bracket 30 near the desired
mounting surface of the side rail 40 at an appropriate location to
be welded. With a minimal gap between the bracket 30 and the side
rail 40, a welding robot 50 is set to weld the bracket 30 to the
side rail 40 while the bracket 30 is held in the desired position
by the adjustable tool 20 on the robotic arm 10.
[0037] The positioning and welding system for welding a bracket 30
to a mounting surface uses the adjustable tool 20 on a robotic arm
10 to allow the bracket 30 to pivot on an axis to minimize the gap
between the bracket 30 and its intended mounting surface.
[0038] The adjustable tool 20 can use its grip 18 to secure the
bracket 30. The robotic arm 10 moves the adjustable tool 20 near
the mounting surface. A pivot pin 16 ideally allows the adjustable
tool 20 to pivot relative to a preferred appendage 12 on the distal
end of the robotic arm 10. The appendage 12 may have a height
adjustor 22 to precisely move the bracket 30 linearly relative to
the robotic arm 10. The system allows the bracket 30 to move and
pivot for a precise surface match with the mounting surface without
being forced with substantial pressure against the mounting
surface. Input from the measurement system 44 can automatically
adjust the adjustable tool 20 or the adjustable tool 20 can be
placed in close proximity to the mounting surface with slight or no
pressure, and then may be measured by another measurement system 46
regarding the gap. A welding robot 50 welds the bracket 30 to the
mounting surface with the gap minimized while the bracket 30 is
held in the desired position.
[0039] In the bracket positioning step, the measurement system 46
can receive the bracket positions from the first step and can use
software code for "offsetting robot positions." One or more
measurement system 44, 46 or 48 ideally measures and positions the
robotic arm 10 and thus the bracket 30 relative to the side rail
40.
[0040] In the bracket welding step, a welding robot 50 preferably
receives input from the second measurement system 46 or 48, such as
measuring the gap, and precisely welds the bracket 30 at the
desired position on the mounting surface, such as a side rail 40.
The second measurement system 46 or 48 can preferably be a vision
system.
[0041] FIG. 5 shows a combination end 60 with a bracket-loading
adjustable tool 20, a second measurement system 46 and/or 48, and a
welding robot 50 incorporated into a single tool adapted to operate
on a distal end of the robotic arm 10. The welding robot 50 as
shown can move in all directions relative to the base of the
combination end 60, and the adjustable tool 20, which would be
stationary during welding to hold the bracket 30 in place with the
adjustable tool 20. While requiring specialized combination
tooling, the robotic arm 10 with the combination end 60 can handle
both placement and welding functions to avoid a second robot,
requiring less floor space.
[0042] This disclosure has been described as having exemplary
embodiments and is intended to cover any variations, uses, or
adaptations using its general principles. It is envisioned that
those skilled in the art may devise various modifications and
equivalents without departing from the scope of the disclosure as
recited in the following claims. Further, this disclosure is
intended to cover such variations from the present disclosure as
come within the known or customary practice within the art to which
it pertains.
* * * * *