US20020008004A1 - Method and apparatus for providing parts to workpieces - Google Patents
Method and apparatus for providing parts to workpieces Download PDFInfo
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- US20020008004A1 US20020008004A1 US09/970,255 US97025501A US2002008004A1 US 20020008004 A1 US20020008004 A1 US 20020008004A1 US 97025501 A US97025501 A US 97025501A US 2002008004 A1 US2002008004 A1 US 2002008004A1
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- channel
- piston rod
- bin
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Classifications
-
- 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
-
- 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
- B23P19/002—Article feeders for assembling machines orientating the articles
-
- 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
-
- 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
- B23P19/007—Picking-up and placing mechanisms
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/02—Devices for feeding articles or materials to conveyors
- B65G47/04—Devices for feeding articles or materials to conveyors for feeding articles
- B65G47/12—Devices for feeding articles or materials to conveyors for feeding articles from disorderly-arranged article piles or from loose assemblages of articles
- B65G47/14—Devices for feeding articles or materials to conveyors for feeding articles from disorderly-arranged article piles or from loose assemblages of articles arranging or orientating the articles by mechanical or pneumatic means during feeding
- B65G47/1407—Devices for feeding articles or materials to conveyors for feeding articles from disorderly-arranged article piles or from loose assemblages of articles arranging or orientating the articles by mechanical or pneumatic means during feeding the articles being fed from a container, e.g. a bowl
- B65G47/1414—Devices for feeding articles or materials to conveyors for feeding articles from disorderly-arranged article piles or from loose assemblages of articles arranging or orientating the articles by mechanical or pneumatic means during feeding the articles being fed from a container, e.g. a bowl by means of movement of at least the whole wall of the container
- B65G47/1421—Vibratory movement
Definitions
- the present invention relates to a method and apparatus for conveying, feeding and positioning parts to workpieces.
- the parts are to be welded onto the workpieces.
- the method and apparatus includes a vibratory bin for orientating the parts, a conveyance and feed system for conveying and feeding the parts one at a time to a positioning cylinder which moves the individual parts to the workpieces.
- the vibratory bowl moves the parts into a row and uses a gauge to ensure that the parts have the correct orientation.
- the conveyance and feed system moves the parts from the bowl to the positioning cylinder, separates the parts and holds the parts to ensure that the individual parts are fed at a predetermined rate to the positioning cylinder.
- the positioning cylinder moves each separate part to each workpiece and deposits the part on the workpiece.
- the positioning cylinder uses magnetism to hold the parts during movement of the parts toward the workpieces.
- the positioning cylinder then uses the forward inertia of the parts to deposit the parts on the workpieces.
- Kondo describes a stud welding apparatus which uses an electromagnet to pull and hold the flanged stud in the collet.
- the stud is also held in the collet by the gripping force of a resilient gripper located in the bore of the collet.
- the apparatus uses a pneumatic piston to move the collet with the stud toward the panel to which the stud is to be mounted.
- Naruse et al describes a projection welder for welding a nut to one side of a work.
- the welder includes a parts feeder connected by a flexible feeder tube to a feeder head which feeds nuts to the lower electrode of the welder.
- a signal to the succeeding nut is emitted.
- the electromagnetic coil is energized to magnetize the push rod so that the shoulder surface at the front end portion of the push rod is also magnetized.
- the cylinder is activated to move the piston rod, the connector and the push rod forward which moves the front end portion of the push rod into the lower part of the chute through an opening.
- the nut turning portion at the front end portion of the push rod is inserted into the threaded hole in the lowermost nut in the chute and the shoulder surface on the push rod is brought into abutment engagement with the lowermost nut whereby the nut is magnetically held on the nut turning portion.
- Hamada shows a parts feeder having a vibrating bowl.
- the bowl has a helical parts feeding track extending from the center of the inner bottom of the bowl helically up to a parts outlet in an upper peripheral wall of the bowl.
- Caffa shows a vibrating bowl which has a spiral track mounted on the inside.
- the bowl can have auxiliary devices fitted on any point of the inner wall of the container.
- the devices may be orientating means, overflows, level indicators, sensors, selectors, orientating and selector devices, automatic column breakers, gauges, counters, etc. which allow for counting the workpieces, determining the absence or presence of workpieces and keeping account of the features of the workpieces.
- Mergl shows the use of gravity and pressurized air to move workpieces along the chute components of a feed system.
- the present invention is a method and apparatus for conveying, feeding and positioning correctly orientated parts to workpieces.
- the method and apparatus uses a vibratory bowl to arrange the parts in a single file row.
- the bowl has a gauge which removes parts having the incorrect orientation from the row. It is important to correctly orient the parts to ensure correct operation of the remainder of the apparatus and to ensure that the parts are positioned on the workpieces with the correct orientation.
- the vibratory bowl allows for quick and accurate sorting and orientating of the parts.
- the parts move from the bowl into a conveyance and feed system.
- the conveyance and feed system moves the parts from the bowl to the positioning cylinder and ensures that the parts are fed at correct intervals at the positioning cylinder.
- the conveyance and feed system uses an escapement to separate and feed the individual parts.
- the escapement uses a series of pneumatic pistons to hold the parts and block the path of the parts to prevent the parts from randomly moving to the positioning cylinder.
- the positioning cylinder moves the parts from the conveyance and feed system to the workpieces and deposits the parts on the workpieces.
- the positioning cylinder uses magnetic attraction between the parts and a portion of the piston rod of the positioning cylinder to hold the parts on the piston rod.
- the magnetic attraction enables the positioning cylinder to move the parts to the workpieces at any angle without fear that gravity will act to move the parts off the piston rod.
- the strength of the magnetic attraction is such that the parts will move off the piston rod due to the forward inertia of the parts when the positioning rod stops moving forward.
- FIG. 1 is a perspective view of the apparatus 10 without the positioning cylinder 82 showing the vibratory bowl 12 and the escapement 44 .
- FIG. 2 is a perspective view of the vibratory bowl 12 showing the level sensor 26 .
- FIG. 3 is an enlarged, cross-sectional view along the line 3 - 3 of FIG. 2 showing the parts outlet 20 in the vibratory bowl 12 , the connection of the conveyor conduit 34 and the air assist jet 21 .
- FIG. 4 is a front view of the positioning cylinder 82 and the end track 72 having a cut away cross-sectional portion showing the electromagnet 112 and the parts 150 and showing the movement of the piston rod 100 and holding door 118 in phantom.
- FIG. 4A is an exploded view of the end track 72 showing the part positioner 78 .
- FIG. 5 is a cross-sectional view of the positioning cylinder 82 showing the piston 90 , the piston rod 100 and the tip 104 .
- FIG. 5A is a side view of an extension 202 of an alternate embodiment.
- FIG. 6 is a cross-sectional view of the escapement 44 in the initial, start up position showing the first and second piston blocks 60 and 62 extended into the passageway 50 .
- FIG. 7 is a cross-sectional view of the escapement 44 showing the first piston block 60 extended into the passageway 50 and the second piston block 62 retracted to allow the parts 150 to move along the passageway 50 .
- FIG. 8 is a cross-sectional view of the escapement 44 showing the second piston block 62 partially extended into the passageway 50 such as to contact and hold the second part 150 F in the passageway 50 .
- FIG. 9 is a cross-sectional view of the escapement 44 showing the first piston block 60 retracted to allow the first part 150 E to exit the escapement 44 and the second piston block 62 partially extended to hold the second part 150 F in the passageway 50 in the escapement 44 .
- FIG. 10 is a top view of the gauge 16 of the first embodiment showing parts 150 having correct and incorrect orientations 150 A and 150 B.
- FIG. 11 is a cross-sectional view along the line 11 - 11 of FIG. 10 showing the gauge 16 with a part 150 having an incorrect orientation 150 B.
- FIG. 12 is a cross-sectional view along the line 12 - 12 of FIG. 10 showing the gauge 16 with a part 150 moving along the gauge 16 having a correct orientation 150 A.
- FIG. 13 is a top view of the gauge 216 of the second embodiment with the parts 250 in the correct and incorrect orientations 250 A and 250 B.
- FIG. 14 is a cross-sectional view along the line 14 - 14 of FIG. 13 showing the parts 250 having the correct orientation 250 A.
- FIG. 15 is a cross-sectional view along the line 15 - 15 of FIG. 13 showing the parts 250 having an incorrect orientation 250 B.
- FIG. 16 is a top view of the gauge 316 of the third embodiment showing the ejector 322 and parts 350 having correct and incorrect orientations 350 A and 350 B.
- FIG. 17 is a cross-sectional view along the line 17 - 17 of FIG. 16 showing the parts 350 having the incorrect orientation 350 B.
- FIG. 18 is a cross-sectional view along the line 18 - 18 of FIG. 16 showing the parts 350 having the correct orientation 350 A.
- FIG. 19 is a top view of the gauge 416 of the fourth embodiment showing parts 450 having correct and incorrect orientations 450 A and 450 B.
- FIG. 20 is a cross-sectional view along the line 20 - 20 of FIG. 19 showing the parts 450 having the correct orientation 450 A.
- FIG. 21 is a cross-sectional view along the line 21 - 21 of FIG. 19 showing the parts 450 having the incorrect orientation 450 B.
- the present invention relates to an apparatus for sorting, feeding and positioning parts for attaching to workpieces, which comprises: a vibrating bin for sorting and orientating the parts into a row and moving the row of parts to an opening in the bin wherein the parts in the row have a similar orientation such that as the parts move through the opening in the bin, the parts have the same orientation; a conveyor means having opposed ends with one end adjacent the opening of the bin for moving the parts away from the bin; and a piston means located at the other end of the conveyor means for moving the parts from the conveyor means to the workpieces and positioning the parts on the workpieces at a specific point with a specific orientation, the piston means having a piston rod which holds the parts and an electromagnetic means for magnetizing a portion of the piston rod for holding the part adjacent the portion of the piston rod wherein the piston rod moves in a forward direction to position the parts adjacent the workpieces and stops moving to deposit the parts on the workpieces.
- the present invention relates to a piston apparatus for positioning parts for mounting on workpieces, which comprises: a piston cylinder having a first end and a second end; a piston rod having a first end and a second end with the first end slidably mounted in the piston cylinder for movement between the ends of the piston cylinder such that the piston rod moves along a longitudinal axis of the cylinder, the second end of the piston rod having a size such as to be easily inserted into an opening in the parts; and an electromagnetic means mounted on the piston cylinder adjacent the second end of the piston cylinder for magnetizing a portion of the piston rod adjacent the second end of the piston rod such that the parts are held adjacent the second end of the piston rod by magnetic attraction between the parts and the portion of the piston rod.
- the present invention relates to a method for positioning and mounting parts on workpieces, which comprises the steps of: providing a vibrating bin for sorting and orientating the parts into a row and moving the row of parts to an opening in the bin wherein the parts in the row have a similar orientation such that as the parts move through the opening in the bin, the parts have the same orientation; a conveyor means having opposed ends with one end adjacent the opening of the bin for moving the parts away from the bin; and a piston means located at the other end of the conveyor means for moving the parts from the conveyor means to the workpieces and positioning the parts on the workpieces at a specific point with a specific orientation, the piston means having a piston rod which holds the parts and an electromagnetic means for magnetizing a portion of the piston rod for holding the part adjacent the portion of the piston rod wherein the piston rod moves in a forward direction to position the parts adjacent the workpieces and stops moving to deposit the parts on the workpieces; feeding the parts into the bin; sorting the parts in the bin such that the parts
- the present invention relates to a apparatus for sorting and orientating parts, which comprises: a vibrating bin having an open top and a closed bottom with a sidewall extending therebetween having an inner surface, the sidewall having an opening adjacent the open top of the bin; a channel means mounted on the inner surface of the bin for moving the parts in a row from the bottom of the bin toward the top of the bin; and a gauge means mounted in the channel for removing the parts from the channel which have an incorrect orientation wherein the bin vibrates such as to move the parts along the channel from the bottom of the bin toward the opening in the sidewall of the bin and wherein the gauge acts to engage the parts such that parts having an incorrect orientation are removed from the channel and deposited back toward the bottom of the bin.
- the present invention relates to a method for sorting and orientating parts, which comprises: a vibrating, bin having an open top and a closed bottom with a sidewall extending therebetween having an inner surface, the sidewall having an opening adjacent the open top of the bin; a channel means mounted on the inner surface of the bin for moving the parts in a row from the bottom of the bin toward the top of the bin; and a gauge means mounted in the channel for removing the parts from the channel which have an incorrect orientation wherein the bin vibrates such as to move the parts along the channel from the bottom of the bin toward the opening in the sidewall of the bin and wherein the gauge acts to engage the parts such that parts having an incorrect orientation are removed from the channel and deposited back toward the bottom of the bin; feeding the parts into the bin; and activating the bin such that the bin vibrates and moves the parts along the channel wherein as the parts move along the channel the parts move across the gauge which removes parts having the incorrect orientation from the channel and wherein parts having an incorrect orientation are moved out of the bin
- the present invention relates to a apparatus for feeding parts at a predetermined rate, which comprises: a housing having opposed open ends with a bore extending therebetween along a longitudinal axis of the apparatus; a first piston means mounted between the ends of the housing such as to extend perpendicular to the longitudinal axis of the housing wherein when the first piston means is extended, the first piston means extends into the channel; and a second piston means mounted between the ends of the housing adjacent to and spaced apart from the first piston means such as to extend perpendicular to the longitudinal axis of the housing wherein when the second piston means is extended the second piston means extends into the channel.
- the present invention relates to a method for separating and feeding parts at a predetermined rate, which comprises the steps of: providing a housing having opposed open ends with a bore extending therebetween along a longitudinal axis of the apparatus; a first piston means mounted between the ends of the housing such as to extend perpendicular to the longitudinal axis of the housing wherein when the first piston means is extended, the first piston means extends into the channel; and a second piston means mounted between the ends of the housing adjacent to and spaced apart from the first piston means such as to extend perpendicular to the longitudinal axis of the housing wherein when the second piston means is extended the second piston means extends into the channel; activating the first piston means such that the first piston extends into the channel and prevents the parts from moving beyond the first piston means in the channel; feeding a row of parts into the channel of the housing through one open end; activating the second piston means such as to extend the second piston means into the channel such that a first part is located between the first and second piston means and wherein the
- the apparatus 10 of the present invention is used to position a part 150 , 250 , 350 or 450 on a workpiece 160 .
- the part 150 , 250 , 350 or 450 must be positioned on the workpiece 160 with the correct orientation and must be deposited on the workpiece 160 at a predetermined rate so that each workpiece 160 receives only one part 150 , 250 , 350 or 450 .
- the apparatus 10 includes a vibratory bowl 12 , a conveyance and feed system and a positioning cylinder 82 .
- the vibratory bowl 12 is preferably mounted on a table or frame 162 above a ground surface (FIG. 1)
- the vibratory bowl 12 is preferably mounted on the table 162 with resilient blocks or shocks (not shown) spaced between the bowl 12 and the table 162 .
- the shocks reduce the vibration of the frame 162 and noise of the apparatus 10 .
- the bowl 12 has an electromagnet (not shown) with sheet springs (not shown) to vibrate the bowl 12 and effectively move the parts 150 , 250 , 350 or 450 along the ramp 14 .
- the vibrating mechanism is preferably similar to vibrating mechanisms for vibratory bowls well known in the art.
- a hopper 164 for supplying parts 150 , 250 , 350 or 450 to the bowl 12 is positioned above the bowl 12 (FIGS. 1 and 2).
- the hopper 164 is preferably also mounted on the table 162 .
- the hopper 164 is spaced above and to one side of the bowl 12 .
- the hopper 164 preferably has an outlet ramp 164 A which directs the parts 150 , 250 , 350 or 450 toward the center of the bottom 12 A of the bowl 12 .
- the hopper 164 is preferably mounted at about a 70 angle downward from the horizontal at the top 12 B of the bowl 12 .
- the hopper 164 has a size of 1 ⁇ 4 cubic foot or larger.
- the vibratory bin or bowl 12 preferably has a closed bottom 12 A and an open top 12 B with a sidewall 12 C extending therebetween.
- the bowl 12 has a circular cross-section.
- the inner surface of the sidewall 12 C preferably has a concave curvature.
- the bowl 12 has a diameter of 12.0 inches (30.5 cm).
- a ramp or track 14 is mounted on the inner surface of the sidewall 12 C of the bowl 12 and extends in an upward spiral from the bottom 12 A of the bowl 12 to a parts outlet or opening 21 in the sidewall 12 C of the bowl 12 adjacent the open top 12 B of the bowl 12 (FIG. 2).
- the ramp 14 preferably extends 21 ⁇ 4 revolutions around the inner surface of the sidewall 12 C.
- the first revolution of the ramp 14 preferably begins at the bottom 12 A of the bowl 12 and extends to about 2.250 inches (5.715 cm) above the bottom 12 A of the bowl 12 .
- the second revolution extends from about 2.250 inches (5.715 cm) above the bottom 12 A of the bowl 12 to about 4.000 inches (10.160 cm) above the bottom 12 A of the bowl 12 .
- the last quarter revolution of the ramp 14 about half way between the gauge 16 , 216 , 316 or 416 and the end of the ramp 14 preferably remains level at 4.000 inches (10.16 cm) above the bottom 12 A of the bowl 12 .
- the sidewall 12 C of the bowl 12 has a height of 5.00 inches (12.70 cm) from the bottom 12 A of the bowl 12 and the ramp 14 has an upward angle of incline of about 4.75°.
- the sidewall 12 C of the bowl 12 can also extend below the bottom 12 A of the bowl 12 .
- the ramp 14 is preferably angled with respect to the sidewall 12 C of the bowl 12 .
- the ramp 14 has an upward angle of 95° from the vertical axis A-A of the sidewall 12 C of the bowl 12 (FIG. 2).
- the parts 150 , 250 , 350 or 450 tend to move toward the sidewall 12 C as they move along the ramp 14 .
- a gauge 16 , 216 , 316 or 416 is provided in the ramp 14 .
- the ramp 14 slants back to level or 90° with the vertical axis A-A of the sidewall 12 C.
- the ramp 14 preferably again slants upward preferably about 120° with respect to the vertical axis A-A of the sidewall 12 C.
- the ramp 14 has a width of 1.00 inches (2.54 cm) for the first 13 ⁇ 4 revolutions up to and after the gauge 16 , 216 , 316 or 416 .
- a portion of the ramp 14 is removed.
- a 4.00 inch (10.16 cm) section of ramp 14 is removed to allow for insertion of the gauge 16 , 216 , 316 or 416 .
- the sidewall 12 C of the bowl 12 preferably remains intact.
- the bottom plate 18 , 218 , 318 or 418 of the gauge 16 , 216 , 316 or 416 preferably has a straight, inner edge adjacent the sidewall 12 C and does not curve with the inner surface of the sidewall 12 C.
- the type of gauge 16 , 216 , 316 or 416 which is used in the bowl 12 depends on the type of part 150 , 250 , 350 or 450 which is to be used in the apparatus 10 .
- the gauge 16 includes a bottom plate 18 having a series of angled grooves 18 A (FIGS. 10 to 12 ).
- the grooves 18 A are angled in the direction of travel of the parts 150 and away from the sidewall 12 C of the bowl 12 .
- the grooves 18 A are of such a width as to accommodate protrusions 150 C on the parts 150 (FIG. 11).
- the gauge 216 includes a bottom plate 218 and a top plate 220 mounted together along one side adjacent the sidewall 12 C of the bowl 12 such as to form a slot 222 between the plates 218 and 220 (FIGS. 13 to 15 ).
- the width of the slot 222 is preferably such as to easily accommodate a flange 250 C on the part 250 .
- the top plate 220 preferably has a width less than the width of the bottom plate 218 (FIG. 13).
- the width of the top plate 220 is such that when the flange 250 C of the part 250 contacts the top plate 220 , the plate 220 moves the part 250 such that the center line P 2 -P 2 of the part 250 is beyond the outer edge 218 A of the bottom plate 218 (FIG. 15).
- the gauge 316 includes a bottom plate 318 and a top plate 320 (FIGS. 16 to 18 ).
- the top plate 320 preferably has a width less than the width of the bottom plate 318 .
- the plates 318 and 320 are preferably mounted together along one side adjacent the sidewall 12 C. In the third embodiment, preferably there is no slot between the plates 318 and 320 .
- the bottom plate 318 of the gauge 316 has a channel 318 B forming a lip 318 C along the outer edge 318 A of the plate 318 opposite the sidewall 12 C of the bowl 12 .
- the lip 318 C preferably has a height approximately equal to the height of a pilot 350 C on the part 350 .
- An ejector 322 is preferably mounted in the channel 318 B of the bottom plate 318 adjacent the connection of the top and bottom plates 318 and 320 .
- the ejector 322 is preferably angled on the leading edge 322 A to move the part 350 toward the lip 318 C on the bottom plate 318 .
- the minimum distance between the ejector 322 and the lip 318 C is equal to or slightly greater than the diameter or width of the pilot 350 C of the part 350 .
- the gauge 416 preferably includes a bottom plate 418 and a top plate 420 (FIGS. 19 to 21 ).
- the plates 418 and 420 are preferably mounted along one side adjacent the sidewall 12 C of the bowl 12 .
- the bottom plate 418 preferably has an opening 418 B spaced between the ends and the edges of the bottom plate 418 .
- the top plate 420 preferably has a width less than the bottom plate 418 but extends over the opening 418 B of the bottom plate 418 .
- the width of the top plate 420 is such as to contact the part 450 to move the part 450 toward the outer edge 418 A of the bottom plate 418 such that a pilot 450 C of the part 450 moves along the outer edge 418 A of the bottom plate 418 .
- the gauges 16 , 216 , 316 or 416 of all four (4) embodiments have the same length such as to be easily exchanged in the bowl 12 .
- the width of the bottom plates 18 , 218 , 318 and 418 of the gauges 16 , 216 , 316 and 416 are preferably all equal or slightly greater than the width of the ramp 14 adjacent the gauge 16 , 216 , 316 or 416 .
- the gauges 16 , 216 , 316 or 416 are preferably constructed of hardened steel.
- a parts outlet 20 is preferably located in the sidewall 12 C of the bowl 12 adjacent the open top 12 B.
- the parts outlet 20 is provided with an air assist jet 21 which provides a stream of air from the inside of the bowl 12 through the parts outlet 20 .
- the size of the parts outlet 20 depends on the size of the part 150 , 250 , 350 or 450 being used. In the preferred embodiment, for parts 150 , 250 , 350 or 450 having an outside diameter of 0.980 inches (2.489 cm) and a height of 0.315 inches (0.800 cm) the outlet 20 has a width of 1.110 inches (2.819 cm) and a height of 0.380 inches (0.965 cm) (FIG. 3).
- the outlet 20 is preferably located in the sidewall 12 C adjacent and slightly above the ramp 14 and spaced between the gauge 16 , 216 , 316 or 416 and the end of the ramp 14 .
- the outlet 20 in the sidewall 12 C is spaced about 6.0 to 8.0 inches (15.2 to 20.3 cm) from the gauge 16 , 216 , 316 or 416 .
- the ramp 14 preferably extends beyond the outlet 20 at least about 2.000 inches (5.080 cm).
- the bowl is a dual feed bowl and the sidewall has two (2) identical parts outlets 20 .
- a bypass block (not shown) is mounted on the ramp adjacent the first outlet. The block acts to move parts away from the sidewall of the bowl such that the parts can move past any parts blocking the first outlet such that the parts can move through the second outlet.
- the bowl 12 has a first wiper 22 and a second wiper 24 mounted on the sidewall 12 C such as to extend across the ramp 14 (FIG. 2).
- the first and second wipers 22 and 24 preferably have a similar construction and perform the same function.
- the second wiper 24 is a back up in case the first wiper 22 does not perform correctly and fully.
- the first wiper 22 is preferably located adjacent and above the ramp 14 after approximately 11 ⁇ 4 rotations of the ramp 14 from the bottom 12 A of the bowl 12 .
- the second wiper 24 is located just before the gauge 16 , 216 , 316 or 416 .
- the wipers 22 or 24 are preferably formed from a rectangular piece of steel.
- the wipers 22 or 24 are preferably mounted at an angle such that the end of the wiper 22 or 24 opposite the sidewall 12 C of the bowl 12 is lower and closer to the ramp 14 than the other end of the wiper 22 or 24 mounted to the sidewall 12 C of the bowl 12 .
- the bowl 12 is also provided with a level sensor 26 which senses the level of parts 150 , 250 , 350 or 450 in the bowl 12 and stops the feed of parts 150 , 250 , 350 or 450 from the hopper 164 into the bowl 12 when the level of parts 150 , 250 , 350 or 450 is too high (FIG. 2).
- the level sensor 26 is a paddle switch which includes a paddle arm 28 which rotates or pivots upward to turn off the hopper 164 when parts 150 , 250 , 350 or 450 begin to fill the bottom 12 A of the bowl 12 (FIG. 2).
- the bottom of the arm 28 preferably has a curved plate 30 which allows parts 150 , 250 , 350 or 450 to move under the arm 28 and pivot the arm 28 without jamming the arm 28 .
- the bowl is also provided with a guide (not shown) spaced adjacent the sidewall 12 C between the gauge 16 , 216 , 316 or 416 and the sidewall 12 C.
- the guide acts to move the parts 150 , 250 , 350 or 450 toward the parts outlet 20 .
- the conveyance and feed system includes a conveyor conduit or chuting 34 extending from the parts outlet 20 in the sidewall 12 C of the bowl 12 to an end track 72 adjacent the positioning cylinder 82 .
- the conveyor conduit 34 is divided into a first section 36 and a second section 38 .
- the first end 36 A of the first section 36 is connected to the parts outlet 20 of the bowl 12 so that the parts 150 , 250 , 350 or 450 easily flow into the end of the conduit 34 (FIG. 3).
- the conduit 34 is preferably securely mounted to the outlet 20 of the bowl 12 by a mounting clamp 40 (FIG. 3).
- the first end 36 A of the first section 36 of the conduit 34 is preferably provided with-a first proximity switch 42 which acts to deactivate the hopper 164 when the first section 36 of the conduit 34 is full of parts 150 , 250 , 350 or 450 .
- the first proximity switch 42 is preferably mounted on the first end 36 A of the first section 36 of the conduit 34 adjacent the outlet 20 in the bowl 12 .
- the first proximity switch 42 is preferably a sensory switch and senses the absence or presence of the parts 150 , 250 , 350 or 450 through the conduit 34 using electricity and magnetism.
- the proximity switch 42 is preferably similar to the IGA 2008ABOA manufactured by Efector, Inc. located in Michigan.
- the first section 36 of the conduit 34 preferably extends downward from the outlet 20 in the bowl 12 such that the parts 150 , 250 , 350 or 450 move along the first section 36 of the conduit 34 due to gravity.
- the first section 36 of the conduit 34 is preferably adjustably mounted to the table or frame 162 (FIG. 2).
- the second end 36 B of the first section 36 of the conduit 34 is connected to the top end 44 A of an escapement or parts feeder 44 .
- the escapement or parts feeder 44 includes a front plate 46 and a back plate 48 with mounting clamps 52 and 54 at each end for attachment of the conduit 34 (FIGS. 6 to 9 ).
- the second end 36 B of the first section 36 of the conduit 34 is mounted by the mounting clamp 52 to the top end 44 A of the escapement 44 .
- the conduit 34 is mounted such that the parts 150 , 250 , 350 or 450 easily flow from the conduit 34 into the passageway 50 (to be described in detail hereinafter) in the escapement 44 without changing orientation.
- a channel 46 A is formed on the inner surface of the front plate 46 on the side adjacent the back plate 48 .
- the channel 46 A extends completely between the ends of the front plate 46 such that when the plates 46 and 48 are mounted together, a passageway 50 is formed through the escapement 44 .
- the top of the channel 46 A adjacent the top end 44 A of the escapement 44 is preferably chamfered to allow for easy entry of the parts 150 , 250 , 350 or 450 into the passageway 50 and to compensate for any misalignment of the parts 150 , 250 , 350 or 450 .
- a first and second piston 56 and 58 are mounted on the outer surface of the back plate 48 on the side opposite the front plate 46 .
- the pistons 56 and 58 are mounted such as to extend perpendicular through the back plate 48 and into the passageway 50 so that when the pistons 56 and 58 are extended, the piston blocks 60 and 62 of the pistons 56 and 58 extend into the passageway 50 .
- the pistons 56 and 58 are mounted in a spaced apart relationship such that the second piston 58 is adjacent the top end 44 A of the escapement 44 and the first piston 56 is adjacent the bottom end 44 B of the escapement 44 .
- the pistons 56 and 58 are spaced apart such that when the piston blocks 60 and 62 are extended into the passageway 50 , a single part 150 E is able to be located in the passageway 50 between the piston blocks 60 and 62 (FIG. 8).
- the piston blocks 60 and 62 are precisely positioned to fit only one and exactly one part 150 E between the blocks 60 and 62 .
- the piston blocks 60 and 62 preferably have a cylindrical shape with a diameter equal to or slightly greater than a diameter of the parts 150 , 250 , 350 or 450 .
- the channel 46 A in the front plate 46 has a width equal to or greater than the diameter of the piston blocks 60 and 62 and slightly greater than the parts 150 , 250 , 350 or 450 such that the piston blocks 60 and 62 can easily extend into the channel 46 A and the parts 150 , 250 , 350 or 450 easily move through the passageway 50 .
- the width of the channel 46 A is such that the parts 150 , 250 , 350 or 450 can not move extraneously, side to side within the channel 46 A.
- the pistons 56 and 58 are of such a length as to be able to extend completely into the channel 46 A.
- the width of the channel 46 A and the size of the piston blocks 60 and 62 preferably depend on the size of the parts 150 , 250 , 350 or 450 .
- the pistons 56 and 58 are preferably pneumatic.
- the plates 46 and 48 are preferably constructed of hardened steel.
- An air jet 64 is preferably mounted on the outer surface of the front plate 46 and is in fluid communication with a passageway 66 located in the front plate 46 of the escapement 44 .
- the outlet of the passageway 66 is in the channel 46 A across from the first piston block 60 .
- the passageway 66 of the air jet 64 is preferably angled such as to provide a stream of air in the direction of movement of the parts 150 , 250 , 350 or 450 (FIG. 9).
- the first end 38 A of the second section 38 of the conduit 34 is mounted to the bottom end 44 B of the escapement 44 using the mounting clamp 54 similarly to the mounting of the second end 36 B of the first section 36 to the top end 44 A of the escapement 44 .
- the second section 38 is mounted such that the parts 150 , 250 , 350 or 450 flow easily from the escapement 44 into the second section 38 of the conduit 34 without changing orientation.
- the second end 38 B of the second section 38 of the conduit 34 is preferably mounted using a mounting clamp 68 to the end track 72 .
- the end track 72 is preferably spaced below the escapement 44 such that the parts 150 , 250 , 350 or 450 flow through the second section 38 of the conduit 34 from the escapement 44 to the end track 72 due to gravity.
- a second proximity switch 70 similar to the first proximity switch 42 is preferably located on the second section 38 of the conduit 34 adjacent the end track 72 (FIG. 4).
- the conduit 34 preferably has a passageway 34 A having a cross-sectional shape similar to the parts 150 , 250 , 350 or 450 .
- the part 150 , 250 , 350 or 450 is a nut and the conduit 34 has a rectangular cross-section.
- the cross-sectional shape and size of the conduit 34 is such that the parts 150 , 250 , 350 or 450 easily move through the passageway 34 A in the conduit 34 but have limited side to side motion and are unable to change orientation in the passageway 34 A of the conduit 34 .
- the conduit 34 is twisted or rotated between the ends such that the parts 150 , 250 , 350 or 450 , have one orientation at the first end 36 A of the first section 36 and have a different orientation as the parts 150 , 250 , 350 or 450 exit the conduit 34 at the second end 38 A of the second section 38 .
- the first and second sections 36 and 38 of the conduit 34 can be separately rotated.
- the conduit 34 would preferably be rotated 1800 such that the orientation of the parts 150 , 250 , 350 or 450 is rotated 180° between the ends of the conduit 34 .
- the first section 36 of the conduit 34 preferably has a length between the ends of about 18.0 to 24.0 inches (45.7 to 61.0 cm).
- the second section 38 of the conduit 34 preferably has a length of between 10 and 30 feet (305 and 914 cm). However, the overall length of the conduit 34 and the length of the individual sections 36 and 38 of the conduit 34 preferably depends on the position of the apparatus 10 with respect to the workpiece 160 .
- the conduit 34 is preferably constructed of a semi-flexible ultra high molecular weight plastic (UHMW). However, the conduit 34 could also be constructed of steel.
- the end track 72 preferably extends from the second end 38 B of the second section 38 of the conduit 34 to adjacent the electromagnet 112 on the end cap 88 of the positioning cylinder 84 (FIG. 4).
- the end track 72 preferably is angled between the ends such as to extend vertically from the second end 38 B of the second section 38 of the conduit 34 and turn to a horizontal position adjacent the electromagnet 112 .
- the shape of the end track 72 depends on the location of the positioning cylinder 84 and the position of the workpiece 160 .
- the end track 72 preferably includes a bottom plate 74 and a top plate 76 .
- the bottom plate 74 has a channel 74 A within which the parts 150 , 250 , 350 or 450 move.
- the top plate 76 covers the channel 74 A.
- the bottom plate 74 of the end track 72 extends from the mounting clamp 68 connecting the second end 38 B of the second section 38 of the conduit 34 to the end track 72 to adjacent the opening 114 B for the piston rod 100 in the electromagnet housing 114 .
- the top plate 76 preferably extends from the mounting clamp 68 to adjacent the electromagnet housing 114 .
- the positioning of the end track 72 ensures that when the parts 150 , 250 , 350 or 450 reach the end of the end track 72 , one part 150 , 250 , 350 or 450 will be closely adjacent the opening 114 B in the housing 114 through which the piston rod 100 will be extended.
- the end of the bottom plate 74 opposite the conduit 34 has a notch 74 B which mounts around a part positioner 78 mounted around the opening 114 B on the electromagnet housing 114 (FIG. 4A).
- the part positioner 78 abuts against a shoulder (not shown) located in the notch 74 B of the bottom plate 74 of the end track 72 .
- the shoulder acts to secure mount and correctly orient the part positioner 78 in the notch 74 B in the bottom plate 74 .
- the mating of the notch 74 B and the part positioner 78 ensures that the end track 72 is correctly positioned with respect to the opening 114 B through which the piston rod 100 will be extended.
- the top plate 76 of the end track 72 is preferably constructed of steel.
- the end of the end track 72 is preferably securely and removably mounted to the housing 114 of the electromagnet 112 .
- a wear plate 80 is mounted between the housing 114 of the electromagnet 112 and the bottom plate 74 of the end track 72 .
- the wear plate 80 has an opening which corresponds to the opening 114 B in the housing 114 .
- the bottom plate 74 , wear plate 80 and part positioner 78 are preferably constructed of hardened steel.
- the positioning cylinder 82 is mounted spaced apart from the table 162 having the vibratory bowl 12 and the escapement 44 adjacent the workpiece 160 .
- the positioning cylinder 82 is preferably located below the vibratory bowl 12 such that the parts 150 , 250 , 350 or 450 move from the bowl 12 through the conduit 34 of the conveyance and feeding system to the end track 72 by gravity.
- the positioning cylinder 82 includes a cylinder 84 , a cylinder piston 90 and a piston rod 100 .
- the cylinder 84 has an essentially rectangular shape with four (4) sidewalls forming a square cross-section.
- the cylinder 84 has an inner bore 84 A extending completely through the cylinder 84 having a cross-sectional shape similar to the cross-sectional shape of the cylinder piston 90 .
- the bore 84 A and piston 90 have a circular cross-section.
- the bore 84 A of the cylinder 84 is closed at each end by end caps 86 and 88 .
- One of the end caps 88 has an opening 88 A extending there through to allow for extension of the piston rod 100 from the cylinder 84 .
- the cylinder 84 preferably has a length of 14.750 inches (37.465 cm) without the end caps 86 and 88 and 15.750 inches (40.005 cm) with the end caps 86 and 88 .
- the diameter of the piston 90 is preferably slightly less than the inner diameter of the bore 84 A of the cylinder 84 .
- the bore 84 A preferably has a diameter of 1.500 inches (3.810 cm).
- the piston 90 preferably has a diameter of 1.230 inches (3.124 cm) and a length of 3.250 inches (8.255 cm) end to end.
- the cylinder piston 90 is slidably mounted in the bore 84 A of the cylinder 84 .
- the cylinder piston 90 includes a bumper 92 and piston seal 94 at each end 90 A and 90 B with a wear strip 96 and magnet 98 spaced between the ends 90 A and 90 B (FIG. 5).
- One of the ends 90 B of the cylinder piston 90 has a threaded bore 90 G which extends coaxial with the longitudinal axis of the piston 90 .
- the piston 90 is preferably fully reversible such as to simplify construction of the cylinder 84 .
- the diameter of the piston 90 remains the same while the diameter of the piston rod 100 , extension 102 and tip 104 (to be described in detail hereinafter) are varied to accommodate different sized parts 150 , 250 , 350 or 450 .
- the bumpers 92 are mounted in grooves 90 C adjacent the ends 90 A and 90 B of the piston 90 .
- the ends 90 A and 90 B of the pistons 90 preferably have a diameter smaller than the diameter of the piston 90 .
- the bumpers 92 extend outward beyond the ends 90 A and 90 B of the piston 90 such that the bumpers 92 make contact with the end caps 86 and 88 of the cylinder 84 and prevent the ends 90 A and 90 B of the piston 90 from making contact with the end caps 86 and 88 .
- the bumpers 92 have an outer diameter less than the diameter of the bore 84 A of the cylinder 84 .
- the bumpers 92 are preferably constructed of nylon.
- the piston seals 94 are mounted in grooves 90 D adjacent each of the bumpers 92 on the side opposite the ends 90 A and 90 B of the cylinder piston 90 .
- the seals 94 have a diameter equal to or greater than the diameter of the bore 84 A.
- the seals 94 are in contact with the inner surface of the bore 84 A.
- the seals 94 prevent air from moving past the piston 90 which allows the air to be used to move the cylinder piston 90 .
- the seals 94 are preferably constructed of nylon.
- a wear strip 96 is removably mounted in a groove 90 E in the piston 90 spaced between the piston seals 94 .
- the wear strip 96 has an outer diameter greater than the diameter of the bore 84 A.
- the wear strip 96 preferably has a circular shape with a slit which allows for easy replacement of the strip 96 in the groove 90 E.
- the wear strip 96 is preferably constructed of a resilient material such as Teflon®.
- the magnet 98 is mounted in a groove 90 F spaced between the wear strip 96 and one of the piston seals 94 .
- the magnet 98 preferably has an outer diameter less than or equal to the diameter of the piston 90 such that when the piston 90 moves in the cylinder 84 , the magnet 98 does not contact the surface of the bore 84 A.
- the piston 90 is preferably constructed of aluminum.
- the piston rod 100 has opposed ends 100 A and 100 B with threads at both ends 100 A and 100 B and is threadably mounted at one end 100 A in the threaded bore 90 G in one end 90 B of the cylinder piston 90 (FIG. 5).
- the diameter of the rod 100 varies depending on the outer diameter of the parts 150 , 250 , 350 or 450 to be positioned.
- the rod 100 preferably has a diameter between about 0.25 to 0.625 inches (0.64 to 1.588 cm).
- the rod 100 preferably has an overall length of about 15.125 inches (38.418 cm) and is constructed of a magnetic material such as steel.
- An extension 102 and tip 104 are mounted on the other end 100 B of the rod 100 opposite the piston 90 .
- the extension 102 has a threaded bore at each end 102 A and 102 B and is threadably mounted at one end 102 A on one threaded end 100 B of the rod 100 .
- the extension 102 preferably has a diameter similar to the diameter of the rod 100 .
- the extension 102 preferably has a length of between 2.50 and 2.00 inches (6.35 to 5.08 cm) depending on the diameter of the rod 100 .
- the length of the extension 102 is preferably inversely proportional to the diameter of the rod 100 .
- the extension 102 is constructed of a magnetic material such as steel.
- the extension 102 is also preferably heat treated to ensure longer use and less wear.
- the tip 104 is preferably threadably mounted in the other end 102 B of the extension 102 opposite the rod 100 .
- the tip 104 has a diameter equal to the diameter of the rod 100 and extension 102 .
- the tip 104 is ground down such as to easily fit within the opening 150 D, 250 D, 350 D or 450 D of the part 150 , 250 , 350 or 450 without extensive movement of the part 150 , 250 , 350 or 450 on the tip 104 .
- the outer diameter of the ground down tip 104 is 0.010 to 0.015 inches (0.025 to 0.038 cm) smaller than the inner diameter of the opening 150 D, 250 D, 350 D or 450 D of the parts 150 , 250 , 350 or 450 .
- the threads are provided with an-adhesive such as Loctites manufactured by Loctite Corporation.
- the end 104 B of the tip 104 opposite the extension 102 is also rounded during grinding to reduce the possibility of damage to the part 150 , 250 , 350 or 450 .
- the length of the tip 104 extending beyond the extension 102 is directly proportional to the diameter of the rod 100 and extension 102 .
- the tip 104 has a length of between about 0.500 to 1.000 inches (1.27 to 2.54 cm).
- the tip 104 is constructed of a nonmagnetic material such as stainless steel.
- the extension 202 has a bore 202 E extending completely through the extension 202 with both ends 202 C and 202 D of the bore 202 E being threaded (FIG. 5A).
- the extension 202 is mounted at one end 202 A to the rod 100 similar to the preferred embodiment.
- the tip 204 is mounted on the other end 202 B of the extension 202 and ground down similarly to the preferred embodiment.
- the extension 202 is constructed of a non-magnetic material such as stainless steel.
- a magnet 203 is inserted into the bore 202 E of the extension 202 and held within the bore 202 E by the rod 200 and tip 204 .
- the magnet 203 replaces the magnetic material of the extension 202 of the preferred embodiment.
- the positioning cylinder 82 is preferably a pneumatic cylinder and has air inlets 106 in one sidewall of the cylinder 84 adjacent each of the end caps 86 and 88 of the positioning cylinder 82 .
- the air inlets 106 preferably provide 20 to 60 lbs. of air to move the piston 90 in each direction within the cylinder 84 .
- Reed switches 108 and 110 are mounted on the outer surface of the cylinder 84 adjacent each end cap 86 and 88 of the positioning cylinder 82 (FIG. 5).
- the switches 108 and 110 are mounted on a sidewall of the cylinder 84 offset from the air inlets 106 90°.
- the reed switches 108 and 110 are preferably similar to the DB54L manufactured by SMC Pneumatic, Inc. located in Marcross, Ga.
- An electromagnet 112 is mounted on the end cap 88 of the positioning cylinder 82 having the opening 88 A for extension of the piston rod 100 .
- the electromagnet 112 includes an outer housing 114 having an inner cavity 114 A within which the coil 116 of the electromagnet 112 is mounted.
- the electromagnet 112 is mounted on the end cap 88 of the positioning cylinder 82 such that the cavity 114 A is adjacent the end cap 88 of the positioning cylinder 82 .
- the cavity 114 A extends only partially through the housing 114 .
- the housing 114 has a square shape and the cavity 114 A has a spherical shape.
- the housing 114 of the electromagnet 112 is constructed of a non-magnetic material such as aluminum.
- the housing 114 has an opening 114 B in the end opposite the cavity 114 A which is coaxial with the center of the cavity 114 A and the piston rod 100 when the electromagnet 112 is mounted on the end cap 88 of the positioning cylinder 82 .
- the size of the electromagnet 112 or number of windings in the coil 116 is preferably determined by the diameter of the piston rod 100 and the size of the part 150 , 250 , 350 or 450 to be positioned. In the preferred embodiment, the same size coil 116 having 2500 windings using #30 or #32 wire is used for a positioning cylinder 82 having a piston rod 100 with a diameter of between about 0.25 and 0.625 inches (0.64 and 1.588 cm).
- a holding door 118 is mounted on a side of the housing 114 opposite the top plate 76 of the end track 72 (FIG. 4).
- the door 118 is L-shaped and is mounted such that one leg 118 A of the door 118 extends adjacent the part positioner 78 mounted on the wear plate 80 adjacent the housing 114 of the electromagnet 112 .
- the door 118 has a notch (not shown) in the end of the one leg 118 A opposite the other leg 118 B. When the door 118 is in the closed position, the notch coincides with the notch 74 B of the bottom plate 74 of the end track 72 and the opening 114 B in the housing 114 of the electromagnet 112 (FIG. 4).
- the notch is of a size as to allow the tip 104 of the piston rod 100 to extend beyond the door 118 while maintaining the part 150 , 250 , 350 or 450 in position adjacent the part positioner 78 .
- the door 118 has a spring (not shown) which biases the door 118 into the closed position when the piston rod 100 is retracted.
- the apparatus 10 is preferably controlled by a PLC micro controller 120 having programmable logic and an externally mounted programmable DTAM (keypad) 122 .
- the micro controller 120 has a variety of timers and variables which can be adjusted for each individual user.
- the PLC micro controller 120 is preferably similar to the micro controller sold under the trademark MICROVIEWTM by Allen-Bradley.
- the apparatus 10 can also be operated manually by the user manually activating the switches.
- the apparatus 10 is powered up and the controller 120 runs through a check of the apparatus 10 using the first and second proximity switches 42 and 70 to determine the status and location of the parts 150 , 250 , 350 or 450 in the apparatus 10 . If both the first and second proximity switches 42 and 70 sense parts 150 , 250 , 350 or 450 then the apparatus 10 is ready to proceed. The apparatus 10 then remains idle until a signal to position a part 150 , 250 , 350 or 450 is received. If no part 150 , 250 , 350 or 450 is sensed by the first proximity switch 42 , then the bowl 12 is activated to supply parts 150 , 250 , 350 or 450 to the first section 36 of the conduit 34 .
- the escapement 44 is preferably placed in the start off position with both piston blocks 60 and 62 fully extended into the passageway 50 of the escapement 44 (FIG. 6).
- the piston blocks 60 and 62 prevent the parts 150 , 250 , 350 or 450 from moving through the escapement 44 and allow the parts 150 , 250 , 350 or 450 to be stacked up in the first section 36 of the conduit 34 .
- the hopper 164 is first provided with a supply of parts 150 , 250 , 350 or 450 .
- the vibratory bowl 12 is activated.
- the hopper 164 is then activated to move the parts 150 , 250 , 350 or 450 from the hopper 164 into the vibratory bowl 12 .
- the micro controller 120 is preferably programmed such that the hopper 164 can only be activated when both the level sensor 26 does not sense parts 150 , 250 , 350 or 450 in the bowl 12 and the bowl 12 is activated.
- the arm 28 of the level sensor 26 contacts the parts 150 , 250 , 350 or 450 in the bottom 12 A of the bowl 12 which acts to pivot the arm 28 upward.
- the level sensor 26 deactivates the hopper 164 which stops the flow of parts 150 , 250 , 350 or 450 into the bowl 12 .
- the activating depth for the parts 150 , 250 , 350 or 450 can be varied by the user.
- the parts 150 , 250 , 350 or 450 are vibrated up and around the ramp 14 inside the bowl 12 .
- the parts 150 , 250 , 350 or 450 move around the ramp 14 , the parts 150 , 250 , 350 or 450 pass by and under the first wiper 22 .
- the positioning of the first wiper 22 with respect to the ramp 14 enables the wiper 22 to remove any parts 150 , 250 , 350 or 450 which form a second layer.
- the positioning of the first wiper 22 also allows the wiper 22 to remove any parts 150 , 250 , 350 or 450 that do not form part of a single file row.
- the first wiper 22 is angled such that the extra parts 150 , 250 , 350 or 450 are smoothly removed from the ramp 14 and deposited back into the bottom 12 A of the bowl 12 .
- the single layer, single file row of parts 150 , 250 , 350 or 450 continues moving along the ramp 14 and moves by and under the second wiper 24 .
- the second wiper 24 operates similarly to the first wiper 22 and removes any excess parts 150 , 250 , 350 or 450 which are not part of the single layer, single file row.
- the second wiper 24 is a back up and the parts 150 , 250 , 350 or 450 are reduced to a single layer, single file row by the first wiper 22 .
- the parts 150 , 250 , 350 or 450 next move past a gauge 16 , 216 , 316 or 416 which removes any parts 150 , 250 , 350 or 450 which are incorrectly orientated.
- the type of gauge 16 , 216 , 316 or 416 which is used depends on the type of part 150 , 250 , 350 or 450 which is being orientated.
- the part 150 is a nut or other type of fastener having protrusions 150 C extending out, parallel to the center axis P 1 -P 1 extending through the center of the center opening 150 D of the nut.
- the angled grooves 18 A of the gauge 16 engage the protrusions 150 C of a part 150 B which is incorrectly orientated with the protrusions 150 C facing downward moves along the gauge 16 .
- the angled grooves 18 A slowly move the part 150 B away from the sidewall 12 C of the bowl 12 and over the outer edge of the gauge 16 . If the part 150 A is correctly orientated with the protrusions 150 C facing upward, the part 150 A moves smoothly along the surface of the gauge 16 toward the parts outlet 20 .
- the part 250 is a hex nut, round nut or other fastener having a flange 250 C on one side of the nut coaxial with the center axis P 2 -P 2 of the nut extending through the center opening 250 D of the nut (FIGS. 13 to 15 ).
- the flange 250 C has a diameter larger than the diameter of the nut.
- the top plate 220 moves the nut such that the center axis P 2 -P 2 extending through the center of the center opening 250 D of the part 250 B is beyond the outer edge 218 A of the bottom plate 218 and the part 250 B falls off the bottom plate 218 due to gravity (FIG. 15).
- the flange 250 C slides in the slot 222 between the plates 218 and 220 . This allows the center part of the part 250 A to be completely on the bottom plate 218 (FIG. 14) such that the part 250 A remains on the gauge 216 and moves toward the parts outlet 20 .
- the part 350 is a hex nut, round nut or other fastener having a pilot 350 C extending around the center opening 350 D of the part 350 (FIGS. 16 to 18 ).
- a part 350 B having an incorrect orientation with the pilot 318 C facing upwards moves along the bottom plate 318 of the gauge 316 , the ejector 322 contacts the part 350 B and moves the part 350 B toward the outer edge 318 A of the bottom plate 318 .
- the ejector 322 moves the part 350 B until the center axis P 3 -P 3 of the part 350 which extends through the center of the center opening 350 D of the part 350 is beyond the outer edge 318 A of the bottom plate 318 and the part 350 B falls off the plate 318 due to gravity (FIG. 17).
- the ejector 322 makes contact with the pilot 350 C and tends to move the part 350 A toward the outer edge 318 A of the bottom plate 318 .
- the lip 318 C at the outer edge 318 A of the bottom plate 318 contacts the pilot 350 C and prevents the part 350 A from moving off the bottom plate 318 .
- the part 350 A can contact the outer edge 320 A of the top plate 320 which assists in moving the part 350 A toward the outer edge 318 A of the bottom plate 318 .
- the part 450 is similar to the part 350 in the third embodiment and is a hex nut, round nut or miscellaneous fastener with a pilot 450 C extending around the center opening 450 D of the nut or fastener (FIGS. 19 to 21 ).
- the part 450 B when the part 450 B is incorrectly orientated with the pilot 450 C facing upwards, the part 450 B does not contact the top plate 420 as the part 450 B moves across the gauge 416 . Therefore, the part 450 B is not correctly positioned on the outer edge 418 A of the bottom plate 418 .
- the part 450 B either falls over and off the outer edge 418 A of the bottom plate 418 or fall inward through the opening 418 B in the bottom plate 418 .
- the part 450 A contacts the top plate 420 which acts to move the part 450 A toward the outer edge 418 A of the bottom plate 418 .
- the part 450 A is moved to a point where the center axis P 4 -P 4 extending through the center of the center opening 450 D of the part 450 is centered over the outer edge 418 A of the bottom plate 418 and the part 450 A does not fall over the edge or through the opening 418 B in the bottom plate 418 and moves along the gauge 416 to the parts outlet 416 .
- the parts 150 , 250 , 350 or 450 move past the gauge 16 , 216 , 316 or 416 , the parts 150 , 250 , 350 or 450 form a single layer, single file row of similarly orientated parts 150 , 250 , 350 or 450 .
- a guide (not shown) can be used adjacent the parts outlet 20 to assist in moving the parts 150 , 250 , 350 or 450 toward the outlet 20 .
- a bypass block adjacent the first opening moves parts outward away from the sidewall of the bowl such that the parts will not be caught or engaged by previous parts which have not yet entered the first opening.
- the bypass block allows for flow of parts to the second opening regardless of whether or not the first opening is backed up with parts.
- a stream of air from the air assist jet 21 within the bowl 12 moves the parts 150 , 250 , 350 or 450 through the outlet 20 .
- the air assist jet 21 creates a venturi effect which helps to move the parts 150 , 250 , 350 or 450 faster through the outlet 20 in the sidewall 12 C.
- the air assist jet 21 provides a constant stream of air to continually move the parts 150 , 250 , 350 or 450 through the outlet 20 .
- the bowl 12 preferably provides a continuous flow of parts 150 , 250 , 350 or 450 through the outlet 20 until the bowl 12 is deactivated or the bowl 12 runs out of parts 150 , 250 , 350 or 450 .
- the parts 150 , 250 , 350 or 450 continue to move from the bowl 12 to the conduit 34 until the first proximity switch 42 deactivates 42 the hopper 164 and the vibratory bowl 12 .
- the proximity switch 42 deactivates the hopper 164 and bowl 12 in response to the continual sensing of a part 150 , 250 , 350 or 450 in the first section 36 of the conduit 34 for a preset amount of time and activates the hopper 164 and bowl 12 in response to a failure to sense a part 150 , 250 , 350 or 450 .
- the proximity switch 42 may also deactivate the bowl 12 and hopper 164 when a timer (not shown) which is started when the apparatus 10 is first activated and a part 150 , 250 , 350 or 450 is not sensed by the proximity switch 42 times out.
- the preset length of time the first proximity switch 42 must read a part 150 , 250 , 350 or 450 continually before turning off the bowl 12 can be varied by the user in the micro controller 120 .
- the location of the switch 42 can also be varied along the length of the first section 36 of conduit 34 .
- the switch 42 is activated when the parts 150 , 250 , 350 or 450 in the first section 36 of the conduit 34 extend completely from the second end 36 B of the first section 36 of the conduit 34 to the switch 42 .
- the life of the bowl 12 and hopper 164 can be extended. Deactivating the bowl 12 and hopper 164 also reduces the overall noise of the apparatus 10 .
- the parts 150 , 250 , 350 or 450 move through the outlet 20 in the sidewall 12 C of the bowl 12 , the parts 150 , 250 , 350 or 450 enter the first end 36 A of the first section 36 of the conduit 34 .
- the conduit 34 is orientated such as to accommodate the parts 150 , 250 , 350 or 450 having the orientation as determined by the bowl 12 .
- the passageway 34 A in the conduit 34 is such that the orientation of the parts 150 , 250 , 350 or 450 within the passageway 34 A remains the same as the parts 150 , 250 , 350 or 450 move through the passageway 34 A.
- the parts 150 , 250 , 350 or 450 move by gravity to the second end 36 B of the first section 36 of the conduit 34 and the top end 44 A of the escapement 44 .
- the first and second pistons 56 and 58 are extended such that the piston blocks 60 and 62 extend into the channel 46 A and block the passageway 50 of the escapement 44 preventing the parts 150 , 250 , 350 or 450 from moving into the escapement 44 (FIG. 6).
- the apparatus 10 will remain idle once the parts 150 , 250 , 350 or 450 are at the top 44 A of the escapement 44 and in the first section 36 of the conduit 34 until the positioning cylinder 82 is activated to position parts 150 , 250 , 350 or 450 such that the second proximity switch 70 fails to sense a part 150 , 250 , 350 or 450 and activates the escapement 44 .
- the escapement 44 is activated to feed parts 150 , 250 , 350 or 450 to the second section 38 of the conduit 34 , as soon as the parts 150 , 250 , 350 or 450 are stacked in the first section 36 of the conduit 34 .
- the escapement 44 is activated, the second piston block 62 is retracted from the passageway 50 of the escapement 44 and the parts 150 , 250 , 350 or 450 move into the passageway 50 until the parts 150 , 250 , 350 or 450 are adjacent the first piston block 60 (FIG. 7).
- the second piston 58 is activated which extends the second piston block 62 into the channel 46 A.
- the block 62 contacts a second part 150 F adjacent and in front of the second piston block 62 and traps and holds the second part 15 OF in the channel 46 A (FIG. 8).
- a first part 150 E is trapped between the first and second piston blocks 60 and 62 in the passageway 50 .
- the first piston 56 is then activated to retract the first piston block 60 from the channel 46 A.
- the air jet 64 provides a stream of air through the passageway 66 into the passageway 50 adjacent the first piston block 60 in the direction of movement of the first part 150 E.
- the air jet 64 creates a venturi which helps to move the first part 150 E quickly out of the escapement 44 .
- the length of time the air jet 64 provides a stream of air can preferably be varied in the controller 120 .
- the second piston 58 is reactivated to retract the second piston block 62 from the passageway 50 .
- Retracting the first piston block 60 allows the second part 150 F to move down in the passageway 50 to the former position of the first part 150 E and a third part 150 G to move into the former position of the second part 150 F. If the positioning cylinder 82 is positioning parts 150 , 250 , 350 or 450 and the second proximity switch 70 is not continually reading parts 150 , 250 , 350 or 450 , the escapement process is then repeated starting with the extension of the second piston block 62 .
- the escapement 44 separates and feeds the parts 150 , 250 , 350 or 450 one at a time to the second section 38 of the conduit 34 and eventually the end track 72 .
- the escapement 44 preferably feeds the parts 150 , 250 , 350 or 450 at a rate of between about 5 and 50 parts 150 , 250 , 350 or 450 per minute. However, preferably the rate of feed can be adjusted by the user.
- the parts 150 , 250 , 350 or 450 exit the escapement 44 ; the parts 150 , 250 , 350 or 450 move along the second section 38 of the conduit 34 to the end track 72 due to gravity.
- the second section 38 of the conduit 34 can be rotated between the ends 36 A and 36 B to change the orientation of the parts 150 , 250 , 350 or 450 .
- the parts 150 , 250 , 350 or 450 are fed to the end track 72 until a part 150 , 250 , 350 or 450 is held in the part positioner 78 and the parts 150 , 250 , 350 or 450 are backed up to the second proximity switch 70 .
- the proximity switch 70 senses a part 150 , 250 , 350 or 450 for a predetermined amount of time, the proximity switch 70 sends a signal to the controller 120 to deactivate the escapement 44 to stop feeding parts 150 , 250 , 350 or 450 into the second section 38 of the conduit 34 .
- the predetermined amount of time can preferably be adjusted by the user.
- the switch 70 if the second proximity switch 70 does not sense a part 150 , 250 , 350 or 450 for a predetermined length of time, the switch 70 sends a signal to the controller 120 to shut down the welder interlink and prevent the welder from welding and the positioning cylinder 82 from extending. This will prevent any workpieces 160 from being welded without parts 150 , 250 , 350 or 450 .
- the timer will reset itself and restart the interlink as soon as the second proximity switch 70 senses a part 150 , 250 , 350 or 450 .
- the predetermined amount of time is 0.5 seconds.
- the end track 72 be full of parts 150 , 250 , 350 or 450 so that the parts 150 , 250 , 350 or 450 will feed properly.
- the escapement 44 will feed one part 150 , 250 , 350 or 450 for every part 150 , 250 , 350 or 450 placed on the workpiece 160 by the positioning cylinder 82 .
- the piston 90 of the positioning cylinder 82 Prior to moving the parts 150 , 250 , 350 or 450 to the end track 72 and the parts positioner 78 , the piston 90 of the positioning cylinder 82 must be all the way to end of the cylinder 84 opposite the end track 72 with the piston rod 100 fully retracted.
- the position of the piston 90 is initially determined when the apparatus 10 first receives the signal to begin operation.
- the position of the piston 90 is determined by a signal from the upper reed switch 108 . If the upper reed switch 108 makes contact with the magnet 98 on the piston 90 , the upper reed switch 108 sends a signal to the controller 120 indicating that the cylinder rod 100 is in the fully retracted position and operation of the apparatus 10 can begin. If the upper reed switch 108 does not make contact with the magnet 98 on the cylinder 84 , then operation of the apparatus 10 is delayed until the cylinder rod 100 is fully retracted.
- the positioning cylinder 82 receives a signal to move the piston 90 to extend the piston rod 100 .
- the piston 90 moves within the cylinder 84
- the piston rod 100 moves out of the cylinder 84 into the electromagnet 112
- the lower reed switch 110 makes contact with the magnet 98 on the piston 90 and sends a signal to the controller 120 to activate the electromagnet 112 .
- the electromagnet 112 When the electromagnet 112 is activated, the electromagnet 112 provides a charge in the piston rod 100 which transfers to the extension 102 mounted on the piston rod 100 which is constructed of a magnetic material. Since the tip 104 is constructed of a non-magnetic material, the tip 104 does not become magnetized. As the piston rod 100 continues to be extended, the tip 104 extends through the opening 150 D, 250 D, 350 D or 450 D in the part 150 , 250 , 350 or 450 which is held adjacent the opening 114 B in the electromagnet housing 114 by the part positioner 78 and the holding door 118 .
- the tip 104 extends into the opening 150 D, 250 D, 350 D or 450 D until the part 150 , 250 , 350 or 450 is adjacent and in contact with the shoulder formed at the connection of the tip 104 and the extension 102 . Since the extension 102 is magnetized, the part 150 , 250 , 350 or 450 is held and in contact with the extension 102 at the end of the tip 104 . The magnetic force of the extension 102 holds the parts 150 , 250 , 350 or 450 on the piston rod 100 with angles up to 850 downward from the horizontal. The electromagnet 112 may not be needed if the angle of placement of the parts 150 , 250 , 350 or 450 does not require additional force to hold the parts 150 , 250 , 350 or 450 on the tip 104 .
- the part 150 , 250 , 350 or 450 and piston rod 100 contact the holding door 118 and pivot the holding door 118 out of the path of the part 150 , 250 , 350 or 450 and piston rod 100 (FIG. 4).
- the rod 100 is extended until the tip 104 and part 150 , 250 , 350 or 450 are adjacent the workpiece 160 .
- the positioning cylinder 82 is positioned such that the piston 90 moves a full stroke to position the part 150 , 250 , 350 or 450 adjacent the workpiece 160 .
- the tip 104 does not come in contact with the workpiece 160 .
- the forward movement of the piston rod 100 is stopped and the forward inertia of the part 150 , 250 , 350 or 450 overcomes the magnetic attraction between the extension 102 and the part 150 , 250 , 350 or 450 and moves the part 150 , 250 , 350 or 450 off the tip 104 and onto the workpiece 160 .
- the magnetic attraction between the extension 102 and the part 150 , 250 , 350 or 450 is chosen such that the forward inertia of the part 150 , 250 , 350 or 450 is sufficient to easily overcome the magnetic attraction.
- the same size coil 116 can be used to move any of the parts 150 , 250 , 350 or 450 to be used in the apparatus 10 .
- the apparatus 10 will preferably operate with standard, round, square or hex weld fasteners having a thread size of ⁇ fraction (3/16) ⁇ to 1 ⁇ 2 or M4 to ML12.
- a piston timer (not shown) is activated which retracts the piston rod 100 after the timer is timed out.
- the electromagnet 112 is also on a timer and is deactivated when the electromagnetic timer (not shown) is timed out. In the preferred embodiment, both of the timers can be adjusted by the user.
- the electromagnet 112 is not deactivated until the part 150 , 250 , 350 or 450 is deposited on the workpiece 160 .
- the electromagnet 112 can be deactivated just prior to depositing the part 150 , 250 , 350 or 450 on the workpiece 160 to ensure that the forward inertia of the part 150 , 250 , 350 or 450 is sufficient to move the part 150 , 250 , 350 or 450 off the tip 104 . It may be necessary to adjust the magnetic timer so that the part 150 , 250 , 350 or 450 will be held on the tip 104 as the rod 100 is extended and will be released from the tip 104 when the part 150 , 250 , 350 or 450 is adjacent the workpiece 160 .
- the electromagnet is not used.
- the strength of the magnet 203 in the extension 202 is chosen such that the forward inertia of the part 150 , 250 , 350 or 450 moves the part 150 , 250 , 350 or 450 off the extension 202 and tip 204 .
- the upper reed switch 108 makes contact with the magnet 98 on the piston 90 and sends a signal to the controller 120 which sends a signal to the user's machine telling it that it is all right to perform its function.
- the length of time between the positioning cylinder 82 returning to the fully retracted position and the signal to the user can be adjusted at the controller 120 .
- the apparatus 10 repeats its operation.
- the apparatus 10 can provide a part 150 , 250 , 350 or 450 to a workpiece 160 at a rate of 5 to 50 parts 150 , 250 , 350 or 450 per minute.
- the apparatus 10 can be used to place a round, square or hex weld fastener or nut on the lower electrode of a resistance welding machine.
- the apparatus 10 can also be used to deposit the part 150 , 250 , 350 or 450 on a pin 166 on a workpiece 160 (FIG. 4).
Abstract
The method and apparatus (10) for moving and positioning parts (150, 250, 350 or 450) on workpieces (160) is described. The apparatus includes a vibratory bowl (12), a conveyance and feed system and a positioning cylinder (82). The bowl aligns the parts and orients the parts using a gauge (16, 216, 316 or 416). The conveyance and feed system moves the parts through a conduit (34) using an escapement (44) to feed the parts one at a time to the positioning cylinder. The positioning cylinder has a pneumatic piston (90) with a piston rod (100) having an extension (102) and tip (104). An electromagnet (112) is mounted at one end of the positioning cylinder. When activated, the positioning cylinder extends the piston rod such that the tip extends into an opening (150D, 250D, 350D or 450D) in the part. The electromagnet is activated simultaneously and sends a charge down the piston rod which charges the extension which is constructed of a magnetic material. The part is held on the tip by the magnetic attraction to the extension. When the forward movement of the piston rod stops, the forward inertia of the part overcomes the magnetic attraction and moves the part off the tip to the workpiece.
Description
- Not Applicable
- Not Applicable
- (1) Field of the Invention
- The present invention relates to a method and apparatus for conveying, feeding and positioning parts to workpieces. In general, the parts are to be welded onto the workpieces. The method and apparatus includes a vibratory bin for orientating the parts, a conveyance and feed system for conveying and feeding the parts one at a time to a positioning cylinder which moves the individual parts to the workpieces. The vibratory bowl moves the parts into a row and uses a gauge to ensure that the parts have the correct orientation. The conveyance and feed system moves the parts from the bowl to the positioning cylinder, separates the parts and holds the parts to ensure that the individual parts are fed at a predetermined rate to the positioning cylinder. The positioning cylinder moves each separate part to each workpiece and deposits the part on the workpiece. The positioning cylinder uses magnetism to hold the parts during movement of the parts toward the workpieces. The positioning cylinder then uses the forward inertia of the parts to deposit the parts on the workpieces.
- (2) Description of the Related Art
- The related art has shown various types of positioning apparatus for positioning parts on workpieces. Illustrative are U.S. Pat. No. 2,623,974 to Prucha; U.S. Pat. No. 3,293,402 to Graham; U.S. Pat. No. 4,020,316 to Schaft et al; U.S. Pat. No. 4,609,805 to Tobita et al; U.S. Pat. No. 4,754,116 to Naruse et al; U.S. Pat. No. 4,789,768 to Tobita et al; U.S. Pat. No. 5,359,171 to Aovama and U.S. Pat. No. 5,688,414 to Kondo.
- In particular, Kondo describes a stud welding apparatus which uses an electromagnet to pull and hold the flanged stud in the collet. The stud is also held in the collet by the gripping force of a resilient gripper located in the bore of the collet. The apparatus uses a pneumatic piston to move the collet with the stud toward the panel to which the stud is to be mounted.
- In addition, Naruse et al describes a projection welder for welding a nut to one side of a work. The welder includes a parts feeder connected by a flexible feeder tube to a feeder head which feeds nuts to the lower electrode of the welder. When the preceding operation has been completed and the upper electrode has been lifted, a signal to the succeeding nut is emitted. Simultaneously, the electromagnetic coil is energized to magnetize the push rod so that the shoulder surface at the front end portion of the push rod is also magnetized. The cylinder is activated to move the piston rod, the connector and the push rod forward which moves the front end portion of the push rod into the lower part of the chute through an opening. Thus, the nut turning portion at the front end portion of the push rod is inserted into the threaded hole in the lowermost nut in the chute and the shoulder surface on the push rod is brought into abutment engagement with the lowermost nut whereby the nut is magnetically held on the nut turning portion.
- The forward movement of the piston rod is continued and the lowermost nut is removed from the chute. When the push rod has been moved to a position in which the front face of the nut is close to the nut centering pin on the lower electrode, a sensor is operated to de-energize the electromagnetic coil so that the push rod is demagnetized. However, the nut is held on the front end portion of the push rod due to the inertia produced by the thrust force of the shoulder surface. The forward movement of the push rod is further continued to bring the front face of the lower part of the nut on the rod into engagement with the nut centering pin so that the movement of the nut is now blocked by the pin. Further movement of the push rod moves the upper part of the nut so that the nut is rotated counterclockwise over an angle of about 90 degrees about the lower part thereof until the nut is placed on the top face of the electrode tip with the threaded hole in the nut receiving the nut centering pin. Thus, the nut makes contact with the lower electrode and is rotated off the end of the rod.
- The related art has also shown several different types of vibrating bowls for use with feed and conveyance machines. Illustrative are U.S. Pat. No. 3,115,239 to Wright; U.S. Pat. No. 3,456,424 to Thurston et al; U.S. Pat. No. 3,457,693 to Jackson; U.S. Pat. No. 3,838,770 to Caffa; U.S. Pat. No. 4,266,653 to Mergl; U.S. Pat. No. 4,629,054 to Kondo; U.S. Pat. No. 4,633,995 to Hamada and U.S. Pat. No. 4,878,575 to McDonald et al.
- In particular, Hamada shows a parts feeder having a vibrating bowl. The bowl has a helical parts feeding track extending from the center of the inner bottom of the bowl helically up to a parts outlet in an upper peripheral wall of the bowl.
- Further, Caffa shows a vibrating bowl which has a spiral track mounted on the inside. The bowl can have auxiliary devices fitted on any point of the inner wall of the container. The devices may be orientating means, overflows, level indicators, sensors, selectors, orientating and selector devices, automatic column breakers, gauges, counters, etc. which allow for counting the workpieces, determining the absence or presence of workpieces and keeping account of the features of the workpieces.
- Finally, Mergl shows the use of gravity and pressurized air to move workpieces along the chute components of a feed system.
- Also of interest is U.S. Pat. No. 5,248,869 to DeBell et al which shows a composite weld nut locating pin.
- There remains the need for an apparatus and method for moving parts to workpieces which has a vibratory bowl for orientating the parts, a feed and conveyance system for moving the individual parts at a predetermined rate from the bowl and a positioning cylinder which holds each individual part using magnetism and which deposits the part on the workpiece using the forward inertia of the part.
- The present invention is a method and apparatus for conveying, feeding and positioning correctly orientated parts to workpieces. The method and apparatus uses a vibratory bowl to arrange the parts in a single file row. The bowl has a gauge which removes parts having the incorrect orientation from the row. It is important to correctly orient the parts to ensure correct operation of the remainder of the apparatus and to ensure that the parts are positioned on the workpieces with the correct orientation. The vibratory bowl allows for quick and accurate sorting and orientating of the parts. The parts move from the bowl into a conveyance and feed system. The conveyance and feed system moves the parts from the bowl to the positioning cylinder and ensures that the parts are fed at correct intervals at the positioning cylinder. The conveyance and feed system uses an escapement to separate and feed the individual parts. The escapement uses a series of pneumatic pistons to hold the parts and block the path of the parts to prevent the parts from randomly moving to the positioning cylinder. The positioning cylinder moves the parts from the conveyance and feed system to the workpieces and deposits the parts on the workpieces. The positioning cylinder uses magnetic attraction between the parts and a portion of the piston rod of the positioning cylinder to hold the parts on the piston rod. The magnetic attraction enables the positioning cylinder to move the parts to the workpieces at any angle without fear that gravity will act to move the parts off the piston rod. The strength of the magnetic attraction is such that the parts will move off the piston rod due to the forward inertia of the parts when the positioning rod stops moving forward.
- The substance and advantages of the present invention will become increasingly apparent by reference to the following drawings and the description.
- FIG. 1 is a perspective view of the
apparatus 10 without thepositioning cylinder 82 showing thevibratory bowl 12 and theescapement 44. - FIG. 2 is a perspective view of the
vibratory bowl 12 showing thelevel sensor 26. - FIG. 3 is an enlarged, cross-sectional view along the line3-3 of FIG. 2 showing the
parts outlet 20 in thevibratory bowl 12, the connection of theconveyor conduit 34 and the air assistjet 21. - FIG. 4 is a front view of the
positioning cylinder 82 and theend track 72 having a cut away cross-sectional portion showing theelectromagnet 112 and theparts 150 and showing the movement of thepiston rod 100 and holdingdoor 118 in phantom. - FIG. 4A is an exploded view of the
end track 72 showing thepart positioner 78. - FIG. 5 is a cross-sectional view of the
positioning cylinder 82 showing thepiston 90, thepiston rod 100 and thetip 104. - FIG. 5A is a side view of an
extension 202 of an alternate embodiment. - FIG. 6 is a cross-sectional view of the
escapement 44 in the initial, start up position showing the first and second piston blocks 60 and 62 extended into thepassageway 50. - FIG. 7 is a cross-sectional view of the
escapement 44 showing thefirst piston block 60 extended into thepassageway 50 and thesecond piston block 62 retracted to allow theparts 150 to move along thepassageway 50. - FIG. 8 is a cross-sectional view of the
escapement 44 showing thesecond piston block 62 partially extended into thepassageway 50 such as to contact and hold thesecond part 150F in thepassageway 50. - FIG. 9 is a cross-sectional view of the
escapement 44 showing thefirst piston block 60 retracted to allow thefirst part 150E to exit theescapement 44 and thesecond piston block 62 partially extended to hold thesecond part 150F in thepassageway 50 in theescapement 44. - FIG. 10 is a top view of the
gauge 16 of the firstembodiment showing parts 150 having correct andincorrect orientations 150A and 150B. - FIG. 11 is a cross-sectional view along the line11-11 of FIG. 10 showing the
gauge 16 with apart 150 having anincorrect orientation 150B. - FIG. 12 is a cross-sectional view along the line12-12 of FIG. 10 showing the
gauge 16 with apart 150 moving along thegauge 16 having a correct orientation 150A. - FIG. 13 is a top view of the
gauge 216 of the second embodiment with theparts 250 in the correct andincorrect orientations - FIG. 14 is a cross-sectional view along the line14-14 of FIG. 13 showing the
parts 250 having thecorrect orientation 250A. - FIG. 15 is a cross-sectional view along the line15-15 of FIG. 13 showing the
parts 250 having anincorrect orientation 250B. - FIG. 16 is a top view of the
gauge 316 of the third embodiment showing theejector 322 andparts 350 having correct andincorrect orientations - FIG. 17 is a cross-sectional view along the line17-17 of FIG. 16 showing the
parts 350 having theincorrect orientation 350B. - FIG. 18 is a cross-sectional view along the line18-18 of FIG. 16 showing the
parts 350 having thecorrect orientation 350A. - FIG. 19 is a top view of the
gauge 416 of the fourthembodiment showing parts 450 having correct andincorrect orientations - FIG. 20 is a cross-sectional view along the line20-20 of FIG. 19 showing the
parts 450 having thecorrect orientation 450A. - FIG. 21 is a cross-sectional view along the line21-21 of FIG. 19 showing the
parts 450 having theincorrect orientation 450B. - The present invention relates to an apparatus for sorting, feeding and positioning parts for attaching to workpieces, which comprises: a vibrating bin for sorting and orientating the parts into a row and moving the row of parts to an opening in the bin wherein the parts in the row have a similar orientation such that as the parts move through the opening in the bin, the parts have the same orientation; a conveyor means having opposed ends with one end adjacent the opening of the bin for moving the parts away from the bin; and a piston means located at the other end of the conveyor means for moving the parts from the conveyor means to the workpieces and positioning the parts on the workpieces at a specific point with a specific orientation, the piston means having a piston rod which holds the parts and an electromagnetic means for magnetizing a portion of the piston rod for holding the part adjacent the portion of the piston rod wherein the piston rod moves in a forward direction to position the parts adjacent the workpieces and stops moving to deposit the parts on the workpieces.
- Further, the present invention relates to a piston apparatus for positioning parts for mounting on workpieces, which comprises: a piston cylinder having a first end and a second end; a piston rod having a first end and a second end with the first end slidably mounted in the piston cylinder for movement between the ends of the piston cylinder such that the piston rod moves along a longitudinal axis of the cylinder, the second end of the piston rod having a size such as to be easily inserted into an opening in the parts; and an electromagnetic means mounted on the piston cylinder adjacent the second end of the piston cylinder for magnetizing a portion of the piston rod adjacent the second end of the piston rod such that the parts are held adjacent the second end of the piston rod by magnetic attraction between the parts and the portion of the piston rod.
- Still further, the present invention relates to a method for positioning and mounting parts on workpieces, which comprises the steps of: providing a vibrating bin for sorting and orientating the parts into a row and moving the row of parts to an opening in the bin wherein the parts in the row have a similar orientation such that as the parts move through the opening in the bin, the parts have the same orientation; a conveyor means having opposed ends with one end adjacent the opening of the bin for moving the parts away from the bin; and a piston means located at the other end of the conveyor means for moving the parts from the conveyor means to the workpieces and positioning the parts on the workpieces at a specific point with a specific orientation, the piston means having a piston rod which holds the parts and an electromagnetic means for magnetizing a portion of the piston rod for holding the part adjacent the portion of the piston rod wherein the piston rod moves in a forward direction to position the parts adjacent the workpieces and stops moving to deposit the parts on the workpieces; feeding the parts into the bin; sorting the parts in the bin such that the parts are aligned in a row and have the same orientation; moving the parts through the opening in the bin into the conveyor means; moving the parts along the conveyor means and feeding the parts individually at a predetermined rate to the piston means; holding the parts adjacent the piston means; activating the electromagnetic means such as to magnetize the portion of the piston rod; activating the piston means such that the piston rod moves toward the parts and contacts the parts and moves the parts to the workpieces; and depositing the parts on the workpieces.
- Further still, the present invention relates to a apparatus for sorting and orientating parts, which comprises: a vibrating bin having an open top and a closed bottom with a sidewall extending therebetween having an inner surface, the sidewall having an opening adjacent the open top of the bin; a channel means mounted on the inner surface of the bin for moving the parts in a row from the bottom of the bin toward the top of the bin; and a gauge means mounted in the channel for removing the parts from the channel which have an incorrect orientation wherein the bin vibrates such as to move the parts along the channel from the bottom of the bin toward the opening in the sidewall of the bin and wherein the gauge acts to engage the parts such that parts having an incorrect orientation are removed from the channel and deposited back toward the bottom of the bin.
- Further still, the present invention relates to a method for sorting and orientating parts, which comprises: a vibrating, bin having an open top and a closed bottom with a sidewall extending therebetween having an inner surface, the sidewall having an opening adjacent the open top of the bin; a channel means mounted on the inner surface of the bin for moving the parts in a row from the bottom of the bin toward the top of the bin; and a gauge means mounted in the channel for removing the parts from the channel which have an incorrect orientation wherein the bin vibrates such as to move the parts along the channel from the bottom of the bin toward the opening in the sidewall of the bin and wherein the gauge acts to engage the parts such that parts having an incorrect orientation are removed from the channel and deposited back toward the bottom of the bin; feeding the parts into the bin; and activating the bin such that the bin vibrates and moves the parts along the channel wherein as the parts move along the channel the parts move across the gauge which removes parts having the incorrect orientation from the channel and wherein parts having an incorrect orientation are moved out of the bin through the opening in the sidewall of the bin.
- Still further, the present invention relates to a apparatus for feeding parts at a predetermined rate, which comprises: a housing having opposed open ends with a bore extending therebetween along a longitudinal axis of the apparatus; a first piston means mounted between the ends of the housing such as to extend perpendicular to the longitudinal axis of the housing wherein when the first piston means is extended, the first piston means extends into the channel; and a second piston means mounted between the ends of the housing adjacent to and spaced apart from the first piston means such as to extend perpendicular to the longitudinal axis of the housing wherein when the second piston means is extended the second piston means extends into the channel.
- Finally, the present invention relates to a method for separating and feeding parts at a predetermined rate, which comprises the steps of: providing a housing having opposed open ends with a bore extending therebetween along a longitudinal axis of the apparatus; a first piston means mounted between the ends of the housing such as to extend perpendicular to the longitudinal axis of the housing wherein when the first piston means is extended, the first piston means extends into the channel; and a second piston means mounted between the ends of the housing adjacent to and spaced apart from the first piston means such as to extend perpendicular to the longitudinal axis of the housing wherein when the second piston means is extended the second piston means extends into the channel; activating the first piston means such that the first piston extends into the channel and prevents the parts from moving beyond the first piston means in the channel; feeding a row of parts into the channel of the housing through one open end; activating the second piston means such as to extend the second piston means into the channel such that a first part is located between the first and second piston means and wherein the second piston means contacts a second part in the channel and holds the second part in place in the channel; deactivating the first piston means such that the first piston means moves out of the channel and the first part between the first and second piston means moves along the channel and out of the apparatus; activating the first piston means such that the first piston means extends into the channel and prevents the parts from moving beyond the second piston means in the channel; and deactivating the second piston means such that the second part is released and moved toward the first piston means and is located between the first and second piston means.
- The
apparatus 10 of the present invention is used to position apart workpiece 160. Thepart workpiece 160 with the correct orientation and must be deposited on theworkpiece 160 at a predetermined rate so that eachworkpiece 160 receives only onepart apparatus 10 includes avibratory bowl 12, a conveyance and feed system and apositioning cylinder 82. - The
vibratory bowl 12 is preferably mounted on a table orframe 162 above a ground surface (FIG. 1) Thevibratory bowl 12 is preferably mounted on the table 162 with resilient blocks or shocks (not shown) spaced between thebowl 12 and the table 162. The shocks reduce the vibration of theframe 162 and noise of theapparatus 10. In the preferred embodiment, thebowl 12 has an electromagnet (not shown) with sheet springs (not shown) to vibrate thebowl 12 and effectively move theparts ramp 14. The vibrating mechanism is preferably similar to vibrating mechanisms for vibratory bowls well known in the art. Ahopper 164 for supplyingparts bowl 12 is positioned above the bowl 12 (FIGS. 1 and 2). Thehopper 164 is preferably also mounted on the table 162. In the preferred embodiment, thehopper 164 is spaced above and to one side of thebowl 12. Thehopper 164 preferably has anoutlet ramp 164A which directs theparts bowl 12. Thehopper 164 is preferably mounted at about a 70 angle downward from the horizontal at the top 12B of thebowl 12. In the preferred embodiment, thehopper 164 has a size of ¼ cubic foot or larger. - As seen in FIG. 2, the vibratory bin or
bowl 12 preferably has aclosed bottom 12A and an open top 12B with asidewall 12C extending therebetween. Thebowl 12 has a circular cross-section. Thus, the inner surface of thesidewall 12C preferably has a concave curvature. In the preferred embodiment, thebowl 12 has a diameter of 12.0 inches (30.5 cm). A ramp ortrack 14 is mounted on the inner surface of thesidewall 12C of thebowl 12 and extends in an upward spiral from the bottom 12A of thebowl 12 to a parts outlet or opening 21 in thesidewall 12C of thebowl 12 adjacent the open top 12B of the bowl 12 (FIG. 2). Theramp 14 preferably extends 2¼ revolutions around the inner surface of thesidewall 12C. The first revolution of theramp 14 preferably begins at the bottom 12A of thebowl 12 and extends to about 2.250 inches (5.715 cm) above the bottom 12A of thebowl 12. The second revolution extends from about 2.250 inches (5.715 cm) above the bottom 12A of thebowl 12 to about 4.000 inches (10.160 cm) above the bottom 12A of thebowl 12. The last quarter revolution of theramp 14 about half way between thegauge ramp 14 preferably remains level at 4.000 inches (10.16 cm) above the bottom 12A of thebowl 12. In the preferred embodiment, thesidewall 12C of thebowl 12 has a height of 5.00 inches (12.70 cm) from the bottom 12A of thebowl 12 and theramp 14 has an upward angle of incline of about 4.75°. Thesidewall 12C of thebowl 12 can also extend below the bottom 12A of thebowl 12. Theramp 14 is preferably angled with respect to thesidewall 12C of thebowl 12. Preferably, theramp 14 has an upward angle of 95° from the vertical axis A-A of thesidewall 12C of the bowl 12 (FIG. 2). Thus, theparts sidewall 12C as they move along theramp 14. Preferably, after about 1¾ revolutions of theramp 14 from the bottom 12A of thebowl 12, agauge ramp 14. At the point where theramp 14 meets thegauge ramp 14 slants back to level or 90° with the vertical axis A-A of thesidewall 12C. After thegauge ramp 14 preferably again slants upward preferably about 120° with respect to the vertical axis A-A of thesidewall 12C. In the preferred embodiment, theramp 14 has a width of 1.00 inches (2.54 cm) for the first 1¾ revolutions up to and after thegauge - To insert the
gauge ramp 14 is removed. Preferably, a 4.00 inch (10.16 cm) section oframp 14 is removed to allow for insertion of thegauge sidewall 12C of thebowl 12 preferably remains intact. Thebottom plate gauge sidewall 12C and does not curve with the inner surface of thesidewall 12C. The type ofgauge bowl 12 depends on the type ofpart apparatus 10. - In a first embodiment, the
gauge 16 includes abottom plate 18 having a series ofangled grooves 18A (FIGS. 10 to 12). Thegrooves 18A are angled in the direction of travel of theparts 150 and away from thesidewall 12C of thebowl 12. Thegrooves 18A are of such a width as to accommodate protrusions 150C on the parts 150 (FIG. 11). - In a second embodiment, the
gauge 216 includes abottom plate 218 and atop plate 220 mounted together along one side adjacent thesidewall 12C of thebowl 12 such as to form aslot 222 between theplates 218 and 220 (FIGS. 13 to 15). The width of theslot 222 is preferably such as to easily accommodate a flange 250C on thepart 250. Thetop plate 220 preferably has a width less than the width of the bottom plate 218 (FIG. 13). The width of thetop plate 220 is such that when the flange 250C of thepart 250 contacts thetop plate 220, theplate 220 moves thepart 250 such that the center line P2-P2 of thepart 250 is beyond theouter edge 218A of the bottom plate 218 (FIG. 15). - In a third embodiment, the
gauge 316 includes abottom plate 318 and a top plate 320 (FIGS. 16 to 18). Thetop plate 320 preferably has a width less than the width of thebottom plate 318. Theplates sidewall 12C. In the third embodiment, preferably there is no slot between theplates bottom plate 318 of thegauge 316 has achannel 318B forming alip 318C along theouter edge 318A of theplate 318 opposite thesidewall 12C of thebowl 12. Thelip 318C preferably has a height approximately equal to the height of apilot 350C on thepart 350. Anejector 322 is preferably mounted in thechannel 318B of thebottom plate 318 adjacent the connection of the top andbottom plates ejector 322 is preferably angled on the leading edge 322A to move thepart 350 toward thelip 318C on thebottom plate 318. The minimum distance between theejector 322 and thelip 318C is equal to or slightly greater than the diameter or width of thepilot 350C of thepart 350. - In a fourth embodiment, the
gauge 416 preferably includes abottom plate 418 and a top plate 420 (FIGS. 19 to 21). Theplates sidewall 12C of thebowl 12. Thebottom plate 418 preferably has anopening 418B spaced between the ends and the edges of thebottom plate 418. Thetop plate 420 preferably has a width less than thebottom plate 418 but extends over theopening 418B of thebottom plate 418. The width of thetop plate 420 is such as to contact thepart 450 to move thepart 450 toward theouter edge 418A of thebottom plate 418 such that apilot 450C of thepart 450 moves along theouter edge 418A of thebottom plate 418. - In the preferred embodiment, the
gauges bowl 12. In addition, the width of thebottom plates gauges ramp 14 adjacent thegauge gauges - A
parts outlet 20 is preferably located in thesidewall 12C of thebowl 12 adjacent the open top 12B. Theparts outlet 20 is provided with anair assist jet 21 which provides a stream of air from the inside of thebowl 12 through theparts outlet 20. The size of theparts outlet 20 depends on the size of thepart parts outlet 20 has a width of 1.110 inches (2.819 cm) and a height of 0.380 inches (0.965 cm) (FIG. 3). Theoutlet 20 is preferably located in thesidewall 12C adjacent and slightly above theramp 14 and spaced between thegauge ramp 14. In the preferred embodiment, theoutlet 20 in thesidewall 12C is spaced about 6.0 to 8.0 inches (15.2 to 20.3 cm) from thegauge ramp 14 preferably extends beyond theoutlet 20 at least about 2.000 inches (5.080 cm). In an alternate embodiment (not shown), the bowl is a dual feed bowl and the sidewall has two (2)identical parts outlets 20. In addition, in the alternate embodiment, a bypass block (not shown) is mounted on the ramp adjacent the first outlet. The block acts to move parts away from the sidewall of the bowl such that the parts can move past any parts blocking the first outlet such that the parts can move through the second outlet. - The
bowl 12 has afirst wiper 22 and asecond wiper 24 mounted on thesidewall 12C such as to extend across the ramp 14 (FIG. 2). The first andsecond wipers second wiper 24 is a back up in case thefirst wiper 22 does not perform correctly and fully. Thefirst wiper 22 is preferably located adjacent and above theramp 14 after approximately 1¼ rotations of theramp 14 from the bottom 12A of thebowl 12. Thesecond wiper 24 is located just before thegauge wipers wipers wiper sidewall 12C of thebowl 12 is lower and closer to theramp 14 than the other end of thewiper sidewall 12C of thebowl 12. - The
bowl 12 is also provided with alevel sensor 26 which senses the level ofparts bowl 12 and stops the feed ofparts hopper 164 into thebowl 12 when the level ofparts level sensor 26 is a paddle switch which includes apaddle arm 28 which rotates or pivots upward to turn off thehopper 164 whenparts arm 28 preferably has a curved plate 30 which allowsparts arm 28 and pivot thearm 28 without jamming thearm 28. - Optionally, the bowl is also provided with a guide (not shown) spaced adjacent the
sidewall 12C between thegauge sidewall 12C. The guide acts to move theparts parts outlet 20. - The conveyance and feed system includes a conveyor conduit or
chuting 34 extending from theparts outlet 20 in thesidewall 12C of thebowl 12 to anend track 72 adjacent thepositioning cylinder 82. Theconveyor conduit 34 is divided into afirst section 36 and asecond section 38. Thefirst end 36A of thefirst section 36 is connected to theparts outlet 20 of thebowl 12 so that theparts conduit 34 is preferably securely mounted to theoutlet 20 of thebowl 12 by a mounting clamp 40 (FIG. 3). - The
first end 36A of thefirst section 36 of theconduit 34 is preferably provided with-afirst proximity switch 42 which acts to deactivate thehopper 164 when thefirst section 36 of theconduit 34 is full ofparts first proximity switch 42 is preferably mounted on thefirst end 36A of thefirst section 36 of theconduit 34 adjacent theoutlet 20 in thebowl 12. Thefirst proximity switch 42 is preferably a sensory switch and senses the absence or presence of theparts conduit 34 using electricity and magnetism. Theproximity switch 42 is preferably similar to the IGA 2008ABOA manufactured by Efector, Inc. located in Michigan. Thefirst section 36 of theconduit 34 preferably extends downward from theoutlet 20 in thebowl 12 such that theparts first section 36 of theconduit 34 due to gravity. Thefirst section 36 of theconduit 34 is preferably adjustably mounted to the table or frame 162 (FIG. 2). Thesecond end 36B of thefirst section 36 of theconduit 34 is connected to thetop end 44A of an escapement orparts feeder 44. - The escapement or
parts feeder 44 includes afront plate 46 and aback plate 48 with mountingclamps second end 36B of thefirst section 36 of theconduit 34 is mounted by the mountingclamp 52 to thetop end 44A of theescapement 44. Theconduit 34 is mounted such that theparts conduit 34 into the passageway 50 (to be described in detail hereinafter) in theescapement 44 without changing orientation. Achannel 46A is formed on the inner surface of thefront plate 46 on the side adjacent theback plate 48. Thechannel 46A extends completely between the ends of thefront plate 46 such that when theplates passageway 50 is formed through theescapement 44. The top of thechannel 46A adjacent thetop end 44A of theescapement 44 is preferably chamfered to allow for easy entry of theparts passageway 50 and to compensate for any misalignment of theparts second piston back plate 48 on the side opposite thefront plate 46. Thepistons back plate 48 and into thepassageway 50 so that when thepistons pistons passageway 50. Thepistons second piston 58 is adjacent thetop end 44A of theescapement 44 and thefirst piston 56 is adjacent thebottom end 44B of theescapement 44. Thepistons passageway 50, asingle part 150E is able to be located in thepassageway 50 between the piston blocks 60 and 62 (FIG. 8). In the preferred embodiment, the piston blocks 60 and 62 are precisely positioned to fit only one and exactly onepart 150E between theblocks parts channel 46A in thefront plate 46 has a width equal to or greater than the diameter of the piston blocks 60 and 62 and slightly greater than theparts channel 46A and theparts passageway 50. However, preferably the width of thechannel 46A is such that theparts channel 46A. Thepistons channel 46A. The width of thechannel 46A and the size of the piston blocks 60 and 62 preferably depend on the size of theparts pistons plates air jet 64 is preferably mounted on the outer surface of thefront plate 46 and is in fluid communication with apassageway 66 located in thefront plate 46 of theescapement 44. In the preferred embodiment, the outlet of thepassageway 66 is in thechannel 46A across from thefirst piston block 60. Thepassageway 66 of theair jet 64 is preferably angled such as to provide a stream of air in the direction of movement of theparts - The
first end 38A of thesecond section 38 of theconduit 34 is mounted to thebottom end 44B of theescapement 44 using the mountingclamp 54 similarly to the mounting of thesecond end 36B of thefirst section 36 to thetop end 44A of theescapement 44. Thesecond section 38 is mounted such that theparts escapement 44 into thesecond section 38 of theconduit 34 without changing orientation. Thesecond end 38B of thesecond section 38 of theconduit 34 is preferably mounted using a mountingclamp 68 to theend track 72. Theend track 72 is preferably spaced below theescapement 44 such that theparts second section 38 of theconduit 34 from theescapement 44 to theend track 72 due to gravity. Asecond proximity switch 70 similar to thefirst proximity switch 42 is preferably located on thesecond section 38 of theconduit 34 adjacent the end track 72 (FIG. 4). - The
conduit 34 preferably has apassageway 34A having a cross-sectional shape similar to theparts part conduit 34 has a rectangular cross-section. The cross-sectional shape and size of theconduit 34 is such that theparts passageway 34A in theconduit 34 but have limited side to side motion and are unable to change orientation in thepassageway 34A of theconduit 34. In one embodiment, theconduit 34 is twisted or rotated between the ends such that theparts first end 36A of thefirst section 36 and have a different orientation as theparts conduit 34 at thesecond end 38A of thesecond section 38. The first andsecond sections conduit 34 can be separately rotated. Theconduit 34 would preferably be rotated 1800 such that the orientation of theparts conduit 34. Thefirst section 36 of theconduit 34 preferably has a length between the ends of about 18.0 to 24.0 inches (45.7 to 61.0 cm). Thesecond section 38 of theconduit 34 preferably has a length of between 10 and 30 feet (305 and 914 cm). However, the overall length of theconduit 34 and the length of theindividual sections conduit 34 preferably depends on the position of theapparatus 10 with respect to theworkpiece 160. Theconduit 34 is preferably constructed of a semi-flexible ultra high molecular weight plastic (UHMW). However, theconduit 34 could also be constructed of steel. - The
end track 72 preferably extends from thesecond end 38B of thesecond section 38 of theconduit 34 to adjacent theelectromagnet 112 on theend cap 88 of the positioning cylinder 84 (FIG. 4). Theend track 72 preferably is angled between the ends such as to extend vertically from thesecond end 38B of thesecond section 38 of theconduit 34 and turn to a horizontal position adjacent theelectromagnet 112. However, the shape of theend track 72 depends on the location of thepositioning cylinder 84 and the position of theworkpiece 160. Theend track 72 preferably includes abottom plate 74 and atop plate 76. Thebottom plate 74 has a channel 74A within which theparts top plate 76 covers the channel 74A. Thebottom plate 74 of theend track 72 extends from the mountingclamp 68 connecting thesecond end 38B of thesecond section 38 of theconduit 34 to theend track 72 to adjacent the opening 114B for thepiston rod 100 in theelectromagnet housing 114. Thetop plate 76 preferably extends from the mountingclamp 68 to adjacent theelectromagnet housing 114. The positioning of theend track 72 ensures that when theparts end track 72, onepart housing 114 through which thepiston rod 100 will be extended. The end of thebottom plate 74 opposite theconduit 34 has anotch 74B which mounts around apart positioner 78 mounted around the opening 114B on the electromagnet housing 114 (FIG. 4A). Thepart positioner 78 abuts against a shoulder (not shown) located in thenotch 74B of thebottom plate 74 of theend track 72. The shoulder acts to secure mount and correctly orient thepart positioner 78 in thenotch 74B in thebottom plate 74. The mating of thenotch 74B and thepart positioner 78 ensures that theend track 72 is correctly positioned with respect to the opening 114B through which thepiston rod 100 will be extended. Thetop plate 76 of theend track 72 is preferably constructed of steel. The end of theend track 72 is preferably securely and removably mounted to thehousing 114 of theelectromagnet 112. Awear plate 80 is mounted between thehousing 114 of theelectromagnet 112 and thebottom plate 74 of theend track 72. Thewear plate 80 has an opening which corresponds to the opening 114B in thehousing 114. Thebottom plate 74, wearplate 80 andpart positioner 78 are preferably constructed of hardened steel. - The
positioning cylinder 82 is mounted spaced apart from the table 162 having thevibratory bowl 12 and theescapement 44 adjacent theworkpiece 160. Thepositioning cylinder 82 is preferably located below thevibratory bowl 12 such that theparts bowl 12 through theconduit 34 of the conveyance and feeding system to theend track 72 by gravity. Thepositioning cylinder 82 includes acylinder 84, acylinder piston 90 and apiston rod 100. Thecylinder 84 has an essentially rectangular shape with four (4) sidewalls forming a square cross-section. Thecylinder 84 has aninner bore 84A extending completely through thecylinder 84 having a cross-sectional shape similar to the cross-sectional shape of thecylinder piston 90. In the preferred embodiment, thebore 84A andpiston 90 have a circular cross-section. Thebore 84A of thecylinder 84 is closed at each end byend caps opening 88A extending there through to allow for extension of thepiston rod 100 from thecylinder 84. Thecylinder 84 preferably has a length of 14.750 inches (37.465 cm) without the end caps 86 and 88 and 15.750 inches (40.005 cm) with the end caps 86 and 88. The diameter of thepiston 90 is preferably slightly less than the inner diameter of thebore 84A of thecylinder 84. Thebore 84A preferably has a diameter of 1.500 inches (3.810 cm). Thepiston 90 preferably has a diameter of 1.230 inches (3.124 cm) and a length of 3.250 inches (8.255 cm) end to end. Thecylinder piston 90 is slidably mounted in thebore 84A of thecylinder 84. Thecylinder piston 90 includes abumper 92 andpiston seal 94 at eachend wear strip 96 andmagnet 98 spaced between theends ends 90B of thecylinder piston 90 has a threaded bore 90G which extends coaxial with the longitudinal axis of thepiston 90. Thepiston 90 is preferably fully reversible such as to simplify construction of thecylinder 84. In the preferred embodiment, the diameter of thepiston 90 remains the same while the diameter of thepiston rod 100,extension 102 and tip 104 (to be described in detail hereinafter) are varied to accommodate differentsized parts bumpers 92 are mounted in grooves 90C adjacent theends piston 90. The ends 90A and 90B of thepistons 90 preferably have a diameter smaller than the diameter of thepiston 90. Thebumpers 92 extend outward beyond theends piston 90 such that thebumpers 92 make contact with the end caps 86 and 88 of thecylinder 84 and prevent theends piston 90 from making contact with the end caps 86 and 88. Thebumpers 92 have an outer diameter less than the diameter of thebore 84A of thecylinder 84. Thebumpers 92 are preferably constructed of nylon. The piston seals 94 are mounted ingrooves 90D adjacent each of thebumpers 92 on the side opposite theends cylinder piston 90. Theseals 94 have a diameter equal to or greater than the diameter of thebore 84A. Consequently, theseals 94 are in contact with the inner surface of thebore 84A. Theseals 94 prevent air from moving past thepiston 90 which allows the air to be used to move thecylinder piston 90. Theseals 94 are preferably constructed of nylon. Awear strip 96 is removably mounted in agroove 90E in thepiston 90 spaced between the piston seals 94. Thewear strip 96 has an outer diameter greater than the diameter of thebore 84A. Thus, as thepiston 90 moves in thebore 84A, thewear strip 96 is in constant contact with the surface of thebore 84A. Thewear strip 96 preferably has a circular shape with a slit which allows for easy replacement of thestrip 96 in thegroove 90E. Thewear strip 96 is preferably constructed of a resilient material such as Teflon®. Themagnet 98 is mounted in agroove 90F spaced between thewear strip 96 and one of the piston seals 94. Themagnet 98 preferably has an outer diameter less than or equal to the diameter of thepiston 90 such that when thepiston 90 moves in thecylinder 84, themagnet 98 does not contact the surface of thebore 84A. Thepiston 90 is preferably constructed of aluminum. - The
piston rod 100 has opposed ends 100A and 100B with threads at both ends 100A and 100B and is threadably mounted at oneend 100A in the threaded bore 90G in oneend 90B of the cylinder piston 90 (FIG. 5). The diameter of therod 100 varies depending on the outer diameter of theparts rod 100 preferably has a diameter between about 0.25 to 0.625 inches (0.64 to 1.588 cm). Therod 100 preferably has an overall length of about 15.125 inches (38.418 cm) and is constructed of a magnetic material such as steel. Anextension 102 andtip 104 are mounted on the other end 100B of therod 100 opposite thepiston 90. Theextension 102 has a threaded bore at eachend end 102A on one threaded end 100B of therod 100. Theextension 102 preferably has a diameter similar to the diameter of therod 100. Theextension 102 preferably has a length of between 2.50 and 2.00 inches (6.35 to 5.08 cm) depending on the diameter of therod 100. The length of theextension 102 is preferably inversely proportional to the diameter of therod 100. Theextension 102 is constructed of a magnetic material such as steel. Theextension 102 is also preferably heat treated to ensure longer use and less wear. Thetip 104 is preferably threadably mounted in theother end 102B of theextension 102 opposite therod 100. Initially, thetip 104 has a diameter equal to the diameter of therod 100 andextension 102. However, after thetip 104 is securely mounted in theextension 102, thetip 104 is ground down such as to easily fit within theopening part part tip 104. Preferably, the outer diameter of the ground downtip 104 is 0.010 to 0.015 inches (0.025 to 0.038 cm) smaller than the inner diameter of theopening parts tip 104 in theextension 102, the threads are provided with an-adhesive such as Loctites manufactured by Loctite Corporation. The end 104B of thetip 104 opposite theextension 102 is also rounded during grinding to reduce the possibility of damage to thepart tip 104 extending beyond theextension 102 is directly proportional to the diameter of therod 100 andextension 102. In the preferred embodiment, thetip 104 has a length of between about 0.500 to 1.000 inches (1.27 to 2.54 cm). Thetip 104 is constructed of a nonmagnetic material such as stainless steel. - In an alternate embodiment, the
extension 202 has abore 202E extending completely through theextension 202 with both ends 202C and 202D of thebore 202E being threaded (FIG. 5A). Theextension 202 is mounted at oneend 202A to therod 100 similar to the preferred embodiment. The tip 204 is mounted on theother end 202B of theextension 202 and ground down similarly to the preferred embodiment. Theextension 202 is constructed of a non-magnetic material such as stainless steel. A magnet 203 is inserted into thebore 202E of theextension 202 and held within thebore 202E by the rod 200 and tip 204. The magnet 203 replaces the magnetic material of theextension 202 of the preferred embodiment. - The
positioning cylinder 82 is preferably a pneumatic cylinder and hasair inlets 106 in one sidewall of thecylinder 84 adjacent each of the end caps 86 and 88 of thepositioning cylinder 82. The air inlets 106 preferably provide 20 to 60 lbs. of air to move thepiston 90 in each direction within thecylinder 84. - Reed switches108 and 110 are mounted on the outer surface of the
cylinder 84 adjacent eachend cap switches cylinder 84 offset from theair inlets 106 90°. The reed switches 108 and 110 are preferably similar to the DB54L manufactured by SMC Pneumatic, Inc. located in Marcross, Ga. - An
electromagnet 112 is mounted on theend cap 88 of thepositioning cylinder 82 having theopening 88A for extension of thepiston rod 100. Theelectromagnet 112 includes anouter housing 114 having aninner cavity 114A within which the coil 116 of theelectromagnet 112 is mounted. Theelectromagnet 112 is mounted on theend cap 88 of thepositioning cylinder 82 such that thecavity 114A is adjacent theend cap 88 of thepositioning cylinder 82. Thecavity 114A extends only partially through thehousing 114. Thehousing 114 has a square shape and thecavity 114A has a spherical shape. Thehousing 114 of theelectromagnet 112 is constructed of a non-magnetic material such as aluminum. Thehousing 114 has an opening 114B in the end opposite thecavity 114A which is coaxial with the center of thecavity 114A and thepiston rod 100 when theelectromagnet 112 is mounted on theend cap 88 of thepositioning cylinder 82. The size of theelectromagnet 112 or number of windings in the coil 116 is preferably determined by the diameter of thepiston rod 100 and the size of thepart positioning cylinder 82 having apiston rod 100 with a diameter of between about 0.25 and 0.625 inches (0.64 and 1.588 cm). - A holding
door 118 is mounted on a side of thehousing 114 opposite thetop plate 76 of the end track 72 (FIG. 4). Thedoor 118 is L-shaped and is mounted such that oneleg 118A of thedoor 118 extends adjacent thepart positioner 78 mounted on thewear plate 80 adjacent thehousing 114 of theelectromagnet 112. Thedoor 118 has a notch (not shown) in the end of the oneleg 118A opposite the other leg 118B. When thedoor 118 is in the closed position, the notch coincides with thenotch 74B of thebottom plate 74 of theend track 72 and the opening 114B in thehousing 114 of the electromagnet 112 (FIG. 4). The notch is of a size as to allow thetip 104 of thepiston rod 100 to extend beyond thedoor 118 while maintaining thepart part positioner 78. Thedoor 118 has a spring (not shown) which biases thedoor 118 into the closed position when thepiston rod 100 is retracted. - The
apparatus 10 is preferably controlled by a PLCmicro controller 120 having programmable logic and an externally mounted programmable DTAM (keypad) 122. Themicro controller 120 has a variety of timers and variables which can be adjusted for each individual user. The PLCmicro controller 120 is preferably similar to the micro controller sold under the trademark MICROVIEW™ by Allen-Bradley. Theapparatus 10 can also be operated manually by the user manually activating the switches. - To begin operation of the
apparatus 10, theapparatus 10 is powered up and thecontroller 120 runs through a check of theapparatus 10 using the first and second proximity switches 42 and 70 to determine the status and location of theparts apparatus 10. If both the first and second proximity switches 42 and 70sense parts apparatus 10 is ready to proceed. Theapparatus 10 then remains idle until a signal to position apart part first proximity switch 42, then thebowl 12 is activated to supplyparts first section 36 of theconduit 34. Theescapement 44 is preferably placed in the start off position with both piston blocks 60 and 62 fully extended into thepassageway 50 of the escapement 44 (FIG. 6). Thus, the piston blocks 60 and 62 prevent theparts escapement 44 and allow theparts first section 36 of theconduit 34. - To provide
parts conduit 34, thehopper 164 is first provided with a supply ofparts vibratory bowl 12 is activated. Thehopper 164 is then activated to move theparts hopper 164 into thevibratory bowl 12. Themicro controller 120 is preferably programmed such that thehopper 164 can only be activated when both thelevel sensor 26 does not senseparts bowl 12 and thebowl 12 is activated. - As the
bowl 12 is filled withparts arm 28 of thelevel sensor 26 contacts theparts bowl 12 which acts to pivot thearm 28 upward. Once thearm 28 pivots upward a set amount, thelevel sensor 26 deactivates thehopper 164 which stops the flow ofparts bowl 12. The activating depth for theparts bowl 12, theparts ramp 14 inside thebowl 12. As theparts ramp 14, theparts first wiper 22. The positioning of thefirst wiper 22 with respect to theramp 14 enables thewiper 22 to remove anyparts first wiper 22 also allows thewiper 22 to remove anyparts first wiper 22 is angled such that theextra parts ramp 14 and deposited back into the bottom 12A of thebowl 12. The single layer, single file row ofparts ramp 14 and moves by and under thesecond wiper 24. Thesecond wiper 24 operates similarly to thefirst wiper 22 and removes anyexcess parts second wiper 24 is a back up and theparts first wiper 22. Theparts gauge parts gauge part - In the first embodiment, the
part 150 is a nut or other type of fastener having protrusions 150C extending out, parallel to the center axis P1-P1 extending through the center of the center opening 150D of the nut. Theangled grooves 18A of thegauge 16 engage the protrusions 150C of apart 150B which is incorrectly orientated with the protrusions 150C facing downward moves along thegauge 16. Theangled grooves 18A slowly move thepart 150B away from thesidewall 12C of thebowl 12 and over the outer edge of thegauge 16. If the part 150A is correctly orientated with the protrusions 150C facing upward, the part 150A moves smoothly along the surface of thegauge 16 toward theparts outlet 20. - In the second embodiment, the
part 250 is a hex nut, round nut or other fastener having a flange 250C on one side of the nut coaxial with the center axis P2-P2 of the nut extending through thecenter opening 250D of the nut (FIGS. 13 to 15). The flange 250C has a diameter larger than the diameter of the nut. When thepart 250B is incorrectly orientated with the flange 250C facing upward, thetop plate 220 of thegauge 216 engages the flange 250C and moves thepart 250B away from thesidewall 12C of thebowl 12 and off theouter edge 218A of thebottom plate 218. Thetop plate 220 moves the nut such that the center axis P2-P2 extending through the center of thecenter opening 250D of thepart 250B is beyond theouter edge 218A of thebottom plate 218 and thepart 250B falls off thebottom plate 218 due to gravity (FIG. 15). When thepart 250A is correctly orientated with the flange 250C adjacent thebottom plate 218, the flange 250C slides in theslot 222 between theplates part 250A to be completely on the bottom plate 218 (FIG. 14) such that thepart 250A remains on thegauge 216 and moves toward theparts outlet 20. - In the third embodiment, the
part 350 is a hex nut, round nut or other fastener having apilot 350C extending around thecenter opening 350D of the part 350 (FIGS. 16 to 18). When apart 350B having an incorrect orientation with thepilot 318C facing upwards, moves along thebottom plate 318 of thegauge 316, theejector 322 contacts thepart 350B and moves thepart 350B toward theouter edge 318A of thebottom plate 318. Theejector 322 moves thepart 350B until the center axis P3-P3 of thepart 350 which extends through the center of thecenter opening 350D of thepart 350 is beyond theouter edge 318A of thebottom plate 318 and thepart 350B falls off theplate 318 due to gravity (FIG. 17). When thepart 350A is correctly orientated with thepilot 350C facing downward, theejector 322 makes contact with thepilot 350C and tends to move thepart 350A toward theouter edge 318A of thebottom plate 318. However, thelip 318C at theouter edge 318A of thebottom plate 318 contacts thepilot 350C and prevents thepart 350A from moving off thebottom plate 318. In addition, thepart 350A can contact theouter edge 320A of thetop plate 320 which assists in moving thepart 350A toward theouter edge 318A of thebottom plate 318. - In the fourth embodiment, the
part 450 is similar to thepart 350 in the third embodiment and is a hex nut, round nut or miscellaneous fastener with apilot 450C extending around thecenter opening 450D of the nut or fastener (FIGS. 19 to 21). In this embodiment, when thepart 450B is incorrectly orientated with thepilot 450C facing upwards, thepart 450B does not contact thetop plate 420 as thepart 450B moves across thegauge 416. Therefore, thepart 450B is not correctly positioned on theouter edge 418A of thebottom plate 418. Consequently, thepart 450B either falls over and off theouter edge 418A of thebottom plate 418 or fall inward through theopening 418B in thebottom plate 418. When thepart 450A is correctly orientated with thepilot 450C facing downwards, thepart 450A contacts thetop plate 420 which acts to move thepart 450A toward theouter edge 418A of thebottom plate 418. Thepart 450A is moved to a point where the center axis P4-P4 extending through the center of thecenter opening 450D of thepart 450 is centered over theouter edge 418A of thebottom plate 418 and thepart 450A does not fall over the edge or through theopening 418B in thebottom plate 418 and moves along thegauge 416 to theparts outlet 416. - Once the
parts gauge parts parts parts ramp 14 optionally, a guide (not shown) can be used adjacent theparts outlet 20 to assist in moving theparts outlet 20. In the alternate embodiment, where the apparatus feeds two parts simultaneously, a bypass block adjacent the first opening moves parts outward away from the sidewall of the bowl such that the parts will not be caught or engaged by previous parts which have not yet entered the first opening. The bypass block allows for flow of parts to the second opening regardless of whether or not the first opening is backed up with parts. - As the
parts outlet 20 in thesidewall 12C, a stream of air from the air assistjet 21 within thebowl 12 moves theparts outlet 20. Theair assist jet 21 creates a venturi effect which helps to move theparts outlet 20 in thesidewall 12C. In the preferred embodiment, the air assistjet 21 provides a constant stream of air to continually move theparts outlet 20. Once thebowl 12 begins to moveparts outlet 20, thebowl 12 preferably provides a continuous flow ofparts outlet 20 until thebowl 12 is deactivated or thebowl 12 runs out ofparts parts bowl 12 to theconduit 34 until thefirst proximity switch 42 deactivates 42 thehopper 164 and thevibratory bowl 12. Theproximity switch 42 deactivates thehopper 164 andbowl 12 in response to the continual sensing of apart first section 36 of theconduit 34 for a preset amount of time and activates thehopper 164 andbowl 12 in response to a failure to sense apart proximity switch 42 may also deactivate thebowl 12 andhopper 164 when a timer (not shown) which is started when theapparatus 10 is first activated and apart proximity switch 42 times out. The preset length of time thefirst proximity switch 42 must read apart bowl 12 can be varied by the user in themicro controller 120. The location of theswitch 42 can also be varied along the length of thefirst section 36 ofconduit 34. In general, theswitch 42 is activated when theparts first section 36 of theconduit 34 extend completely from thesecond end 36B of thefirst section 36 of theconduit 34 to theswitch 42. By activating and deactivating thebowl 12 andhopper 164, the life of thebowl 12 andhopper 164 can be extended. Deactivating thebowl 12 andhopper 164 also reduces the overall noise of theapparatus 10. - As soon as the
parts outlet 20 in thesidewall 12C of thebowl 12, theparts first end 36A of thefirst section 36 of theconduit 34. Theconduit 34 is orientated such as to accommodate theparts bowl 12. Thepassageway 34A in theconduit 34 is such that the orientation of theparts passageway 34A remains the same as theparts passageway 34A. As theparts first end 36A of thefirst section 36 of theconduit 34, theparts second end 36B of thefirst section 36 of theconduit 34 and thetop end 44A of theescapement 44. Initially, as theparts top end 44A of theescapement 44, the first andsecond pistons channel 46A and block thepassageway 50 of theescapement 44 preventing theparts second proximity switch 70 senses apart apparatus 10 will remain idle once theparts escapement 44 and in thefirst section 36 of theconduit 34 until thepositioning cylinder 82 is activated to positionparts second proximity switch 70 fails to sense apart escapement 44. If during the initial start up thesecond proximity switch 70 does not sense apart escapement 44 is activated to feedparts second section 38 of theconduit 34, as soon as theparts first section 36 of theconduit 34. When theescapement 44 is activated, thesecond piston block 62 is retracted from thepassageway 50 of theescapement 44 and theparts passageway 50 until theparts parts passageway 50, thesecond piston 58 is activated which extends thesecond piston block 62 into thechannel 46A. However, due to the positioning and size of the piston block 62-and the size of theparts second piston block 62 is extended, theblock 62 contacts asecond part 150F adjacent and in front of thesecond piston block 62 and traps and holds the second part 15OF in thechannel 46A (FIG. 8). Afirst part 150E is trapped between the first and second piston blocks 60 and 62 in thepassageway 50. Thefirst piston 56 is then activated to retract thefirst piston block 60 from thechannel 46A. This opens thepassageway 50 in theescapement 44 and allows thefirst part 150E to move out of the escapement 44 (FIG. 9). When thefirst piston 56 is retracted, theair jet 64 provides a stream of air through thepassageway 66 into thepassageway 50 adjacent thefirst piston block 60 in the direction of movement of thefirst part 150E. Theair jet 64 creates a venturi which helps to move thefirst part 150E quickly out of theescapement 44. The length of time theair jet 64 provides a stream of air can preferably be varied in thecontroller 120. Once thefirst part 150E has left theescapement 44, thefirst piston 56 is reactivated to extend thefirst piston block 60 into thepassageway 50. Finally, thesecond piston 58 is reactivated to retract thesecond piston block 62 from thepassageway 50. Retracting thefirst piston block 60 allows thesecond part 150F to move down in thepassageway 50 to the former position of thefirst part 150E and athird part 150G to move into the former position of thesecond part 150F. If thepositioning cylinder 82 is positioningparts second proximity switch 70 is not continually readingparts second piston block 62. - The
escapement 44 separates and feeds theparts second section 38 of theconduit 34 and eventually theend track 72. Theescapement 44 preferably feeds theparts parts parts escapement 44; theparts second section 38 of theconduit 34 to theend track 72 due to gravity. If theparts second end 38B of thesecond section 38 of theconduit 34 have the incorrect orientation with regard to thepositioning cylinder 82 and theworkpiece 160, thesecond section 38 of theconduit 34 can be rotated between theends parts - The
parts end track 72 until apart part positioner 78 and theparts second proximity switch 70. When thesecond proximity switch 70 senses apart proximity switch 70 sends a signal to thecontroller 120 to deactivate theescapement 44 to stop feedingparts second section 38 of theconduit 34. As with thefirst proximity switch 42, the predetermined amount of time can preferably be adjusted by the user. In the preferred embodiment, if thesecond proximity switch 70 does not sense apart switch 70 sends a signal to thecontroller 120 to shut down the welder interlink and prevent the welder from welding and thepositioning cylinder 82 from extending. This will prevent anyworkpieces 160 from being welded withoutparts second proximity switch 70 senses apart end track 72 be full ofparts parts escapement 44 will feed onepart part workpiece 160 by thepositioning cylinder 82. Once theend track 72 is full ofparts part part positioner 78 is ready to be moved by thepositioning cylinder 82. - Prior to moving the
parts end track 72 and theparts positioner 78, thepiston 90 of thepositioning cylinder 82 must be all the way to end of thecylinder 84 opposite theend track 72 with thepiston rod 100 fully retracted. The position of thepiston 90 is initially determined when theapparatus 10 first receives the signal to begin operation. The position of thepiston 90 is determined by a signal from theupper reed switch 108. If theupper reed switch 108 makes contact with themagnet 98 on thepiston 90, theupper reed switch 108 sends a signal to thecontroller 120 indicating that thecylinder rod 100 is in the fully retracted position and operation of theapparatus 10 can begin. If theupper reed switch 108 does not make contact with themagnet 98 on thecylinder 84, then operation of theapparatus 10 is delayed until thecylinder rod 100 is fully retracted. - When the
parts end track 72 in thepart positioner 78 and held in place by the holdingdoor 118, thepositioning cylinder 82 receives a signal to move thepiston 90 to extend thepiston rod 100. As thepiston 90 moves within thecylinder 84, thepiston rod 100 moves out of thecylinder 84 into theelectromagnet 112, thelower reed switch 110 makes contact with themagnet 98 on thepiston 90 and sends a signal to thecontroller 120 to activate theelectromagnet 112. When theelectromagnet 112 is activated, theelectromagnet 112 provides a charge in thepiston rod 100 which transfers to theextension 102 mounted on thepiston rod 100 which is constructed of a magnetic material. Since thetip 104 is constructed of a non-magnetic material, thetip 104 does not become magnetized. As thepiston rod 100 continues to be extended, thetip 104 extends through theopening part electromagnet housing 114 by thepart positioner 78 and the holdingdoor 118. Thetip 104 extends into theopening part tip 104 and theextension 102. Since theextension 102 is magnetized, thepart extension 102 at the end of thetip 104. The magnetic force of theextension 102 holds theparts piston rod 100 with angles up to 850 downward from the horizontal. Theelectromagnet 112 may not be needed if the angle of placement of theparts parts tip 104. This would be true when the angle of placement is greater than or above horizontal. As thepiston rod 100 continues to be extended, thepart piston rod 100 contact the holdingdoor 118 and pivot the holdingdoor 118 out of the path of thepart rod 100 is extended until thetip 104 andpart workpiece 160. In the preferred embodiment, thepositioning cylinder 82 is positioned such that thepiston 90 moves a full stroke to position thepart workpiece 160. In the preferred embodiment, thetip 104 does not come in contact with theworkpiece 160. As soon as thetip 104 andparts workpiece 160, the forward movement of thepiston rod 100 is stopped and the forward inertia of thepart extension 102 and thepart part tip 104 and onto theworkpiece 160. The magnetic attraction between theextension 102 and thepart part parts apparatus 10. Theapparatus 10 will preferably operate with standard, round, square or hex weld fasteners having a thread size of {fraction (3/16)} to ½ or M4 to ML12. As soon as the signal is sent to thepositioning cylinder 82 to extend thepiston rod 100, a piston timer (not shown) is activated which retracts thepiston rod 100 after the timer is timed out. Theelectromagnet 112 is also on a timer and is deactivated when the electromagnetic timer (not shown) is timed out. In the preferred embodiment, both of the timers can be adjusted by the user. In the preferred embodiment, theelectromagnet 112 is not deactivated until thepart workpiece 160. However, theelectromagnet 112 can be deactivated just prior to depositing thepart workpiece 160 to ensure that the forward inertia of thepart part tip 104. It may be necessary to adjust the magnetic timer so that thepart tip 104 as therod 100 is extended and will be released from thetip 104 when thepart workpiece 160. In the alternate embodiment using thealternate extension 202, the electromagnet is not used. The strength of the magnet 203 in theextension 202 is chosen such that the forward inertia of thepart part extension 202 and tip 204. When thepositioning cylinder 82 returns to its fully retracted position, theupper reed switch 108 makes contact with themagnet 98 on thepiston 90 and sends a signal to thecontroller 120 which sends a signal to the user's machine telling it that it is all right to perform its function. In the preferred embodiment, the length of time between thepositioning cylinder 82 returning to the fully retracted position and the signal to the user can be adjusted at thecontroller 120. Once the user's machine is done, theapparatus 10 repeats its operation. In the preferred embodiment, theapparatus 10 can provide apart workpiece 160 at a rate of 5 to 50parts - The
apparatus 10 can be used to place a round, square or hex weld fastener or nut on the lower electrode of a resistance welding machine. Theapparatus 10 can also be used to deposit thepart pin 166 on a workpiece 160 (FIG. 4). - It is intended that the foregoing description be only illustrative of the present invention and that the present invention be limited only by the hereinafter appended claims.
Claims (55)
1. An apparatus for sorting, feeding and positioning parts for attaching to workpieces, which comprises:
(a) a vibrating bin for sorting and orientating the parts into a row and moving the row of parts to an opening in the bin wherein the parts in the row have a similar orientation such that as the parts move through the opening in the bin, the parts have the same orientation;
(b) a conveyor means having opposed ends with one end adjacent the opening of the bin for moving the parts away from the bin; and
(c) a piston means located at the other end of the conveyor means for moving the parts from the conveyor means to the workpieces and positioning the parts on the workpieces at a specific point with a specific orientation, the piston means having a piston rod which holds the parts and an electromagnetic means for magnetizing a portion of the piston rod for holding the part adjacent the portion of the piston rod wherein the piston rod moves in a forward direction to position the parts adjacent the workpieces and stops moving to deposit the parts on the workpieces.
2. The apparatus of claim 1 wherein the parts are held on the piston rod by magnetic attraction between the portion of the piston rod and the parts.
3. The apparatus of claim 2 wherein the magnetic attraction between the parts and the portion of the piston rod is of a strength so that when the forward movement of the piston rod is stopped, a forward inertia of the parts is greater than the strength of the magnetic attraction such that the forward inertia acts to move the parts off of the piston rod in the forward direction.
4. The apparatus of claim 1 wherein the piston rod has opposed ends with a tip having a front portion and a back portion formed on one of the ends of the piston rod wherein the back portion is spaced between the front portion and the other of the ends of the piston rod, wherein the back portion has a size greater than the front portion and greater than an opening in the parts such that when the piston rod is moved in the forward direction, the front portion of the tip extends through the opening in the part and the part is abutted against the back portion of the tip and wherein the back portion of the tip is constructed of a magnetizable material and the front portion of the tip is constructed of a non-magnetizable material.
5. The apparatus of claim 1 wherein the bin has a gauge for orientating the parts.
6. The apparatus of claim 5 wherein the gauge has a groove which engages a protrusion on the part when the part has an incorrect orientation such as to move the part out of the row of parts.
7. The apparatus of claim 5 wherein the gauge has an upper plate and a lower plate with a space therebetween wherein the upper plate is mounted above the lower plate and extends over a portion of a width of the lower plate and wherein the parts have a flange and a top portion with the flange being larger than the top portion and wherein when the part is correctly orientated, the flange extends between the plates as the part moves along the gauge and wherein when the part is incorrectly orientated, the flange engages an edge of the top plate which moves the part toward an edge of the lower plate such that the part falls off the lower plate.
8. The apparatus of claim 5 wherein the gauge has an ejector which contacts a flange on the part when the part has an incorrect orientation and moves the part out of the row of parts.
9. The apparatus of claim 1 wherein the conveyor means moves the parts toward the piston means and feeds the parts one at a time to a point adjacent an end of the piston rod such that when the piston rod is moved in the forward direction, the end of the piston rod extends through an opening in the part.
10. The apparatus of claim 9 wherein the conveyor means includes a feed means spaced between the ends of the conveyor means which separates the parts in the row of parts and feeds each of the parts at a predetermined rate to the piston means.
11. The apparatus of claim 10 wherein the feed means has a pair of piston blocks which act to hold and separate the parts such as to feed each of the parts at a predetermined rate to the piston means.
12. The apparatus of claim 11 wherein the feed means has opposed ends with a channel extending between the ends and wherein as the parts move along the channel, the piston blocks move into the channel to block the channel to prevent the parts from exiting the channel.
13. The apparatus of claim 12 wherein the parts enter the channel in a continuous flow and wherein one of the piston blocks acts to prevent a first part from exiting the feed means by blocking the channel and the other one of the piston blocks holds a second part in the channel by coming in contact with the second part to trap the second part in the channel such that when one of the piston blocks is retracted, the first part moves along the channel and exits the feed means while the second part is held in place in the channel by the other one of the piston blocks.
14. The apparatus of claim 13 wherein a stream of air is provided in the channel adjacent one of the piston blocks to assist in moving the first part along the channel and out of the feed means.
15. The apparatus of claim 1 wherein a sensor is mounted on one of the ends of the conveyor means adjacent the opening in the bin for deactivating the bin when the parts in the conveyor means are unable to move beyond the first sensor.
16. The apparatus of claim 10 wherein a sensor is mounted adjacent and spaced apart from the end of the conveyor adjacent the piston means to deactivate the feed means to stop a flow of parts from the feed means when a portion of the conveyor means between the sensor and the end of the conveyor means adjacent the piston means is full with parts.
17. The apparatus of claim 1 wherein an end holder means is mounted on the end of the conveyor means adjacent the piston means and holds the parts in a correct orientation adjacent the piston means such that when the piston rod is moved in a forward direction, an end of the piston rod extends into an opening in the part and moves the part out of the end holder to the workpiece.
18. The apparatus of claim 17 wherein a door is pivotably mounted on the end holder to hold the part adjacent the end of the piston rod and wherein as the piston rod is moved in a forward direction, the door is pivoted out of a path of the piston rod.
19. The apparatus of claim 1 wherein the conveyor means includes a conduit extending between the ends.
20. The apparatus of claim 19 wherein the conduit is semi-flexible and is constructed of ultra high molecular weight plastic.
21. The apparatus of claim 20 wherein the conduit is rotated between the ends of the conveyor means such that the orientation of the part is changed from one of the ends of the conveyor means to the other of the ends of the conveyor means.
22. The apparatus of claim 1 wherein the parts are assisted through the opening in the bin by a stream of air.
23. A piston apparatus for positioning parts for mounting on workpieces, which comprises:
(a) a piston cylinder having a first end and a second end;
(b) a piston rod having a first end and a second end with the first end slidably mounted in the piston cylinder for movement between the ends of the piston cylinder such that the piston rod moves along a longitudinal axis of the cylinder, the second end of the piston rod having a size such as to be easily inserted into an opening in the parts; and
(c) an electromagnetic means mounted on the piston cylinder adjacent the second end of the piston cylinder for magnetizing a portion of the piston rod adjacent the second end of the piston rod such that the parts are held adjacent the second end of the piston rod by magnetic attraction between the parts and the portion of the piston rod.
24. The piston apparatus of claim 23 wherein an end holder means is pivotably mounted adjacent the second end of the piston cylinder and holds the part in position adjacent the second end of the piston rod and wherein the end holder means pivots out of a path of the piston rod as the piston rod is moved in a forward direction.
25. The piston apparatus of claim 23 wherein the second end of the piston rod is formed by a tip having a front portion and a back portion with the back portion spaced between the front portion and the first end of the piston rod, wherein the front portion has a size smaller than a size of the back portion and smaller than a size of an opening in the parts and wherein the size of the back portion is greater than the size of the opening in the parts.
26. The piston apparatus of claim 25 wherein the front portion of the tip is constructed of a non-magnetic material and the back portion of the tip is constructed of a magnetic material such that the back portion of the tip becomes magnetized while the front portion of the tip remains unmagnetized when the electromagnetic means is activated and wherein when the parts are mounted on the tip, the parts are held on the tip by the magnetic attraction between the parts and the back portion of the tip.
27. The piston apparatus of claim 26 wherein the tip and the piston rod are separate pieces.
28. The piston apparatus of claim 27 wherein the piston rod is constructed of a magnetic material.
29. The piston apparatus of claim 23 wherein the piston rod is moved using air.
30. The piston apparatus of claim 23 wherein the piston cylinder is provided with locating switches which activate the electromagnetic means in response to a position of the piston rod within the cylinder.
31. The piston apparatus of claim 25 wherein the parts are nuts and the first portion of the tip of the piston rod extends through the opening in the nut.
32. The piston apparatus of claim 23 wherein when the piston rod is in a fully retracted position, the second end of the piston rod does not extend beyond the second end of the piston cylinder.
33. A method for positioning and mounting parts on workpieces, which comprises the steps of:
(a) providing a vibrating bin for sorting and orientating the parts into a row and moving the row of parts to an opening in the bin wherein the parts in the row have a similar orientation such that as the parts move through the opening in the bin, the parts have the same orientation; a conveyor means having opposed ends with one end adjacent the opening of the bin for moving the parts away from the bin; and a piston means located at the other end of the conveyor means for moving the parts from the conveyor means to the workpieces and positioning the parts on the workpieces at a specific point with a specific orientation, the piston means having a piston rod which holds the parts and an electromagnetic means for magnetizing a portion of the piston rod for holding the part adjacent the portion of the piston rod wherein the piston rod moves in a forward direction to position the parts adjacent the workpieces and stops moving to deposit the parts on the workpieces;
(b) feeding the parts into the bin;
(c) sorting the parts in the bin such that the parts are aligned in a row and have the same orientation;
(d) moving the parts through the opening in the bin into the conveyor means;
(e) moving the parts along the conveyor means and feeding the parts individually at a predetermined rate to the piston means;
(f) holding the parts adjacent the piston means;
(g) activating the electromagnetic means such as to magnetize the portion of the piston rod;
(h) activating the piston means such that the piston rod moves toward the parts and contacts the parts and moves the parts to the workpieces; and
(i) depositing the parts on the workpieces.
34. The method of claim 33 wherein to deposit the parts on the workpieces, the forward movement of the piston rod is stopped once the parts are adjacent the workpieces and wherein a forward inertia of the parts carries the parts off the piston rod and onto the workpieces.
35. The method of claim 33 wherein the piston rod has opposed ends with one of the ends of the piston rod formed by a tip having a back portion and a front portion wherein the back portion is spaced between the other one of the ends of the piston rod and the front portion and wherein the back portion and the piston rod are constructed of a magnetic material and the front portion is constructed of a non-magnetic material so that when the electromagnetic means is activated, the back portion of the tip becomes magnetized such that the parts are held on the tip by the magnetic attraction between the parts and the back portion of the tip.
36. The method of claim 35 wherein a strength of the magnetic attraction between the parts and the back portion of the tip is such that when the forward movement of the piston rod is stopped, a forward inertia of the part is greater than the magnetic attraction acting to hold the part on the pin such that the part moves forward off the tip and onto the workpiece.
37. An apparatus for sorting and orientating parts, which comprises:
(a) a vibrating bin having an open top and a closed bottom with a sidewall extending therebetween having an inner surface, the sidewall having an opening adjacent the open top of the bin;
(b) a channel means mounted on the inner surface of the bin for moving the parts in a row from the bottom of the bin toward the top of the bin; and
(c) a gauge means mounted in the channel for removing the parts from the channel which have an incorrect orientation wherein the bin vibrates such as to move the parts along the channel from the bottom of the bin toward the opening in the sidewall of the bin and wherein the gauge acts to engage the parts such that parts having an incorrect orientation are removed from the channel and deposited back toward the bottom of the bin.
38. The apparatus of claim 37 wherein the gauge has a groove which engages a protrusion on the part and removes the part from the channel when the part has the incorrect orientation.
39. The apparatus of claim 38 wherein the gauge has an upper plate and a lower plate with a space therebetween wherein the upper plate is mounted above the lower plate and extends over a portion of a width of the lower plate and wherein the parts have a flange and a top portion-with the flange being larger than the top portion and wherein when the part is correctly orientated, the flange extends between the plates as the part moves along the gauge and wherein when the part is incorrectly orientated, the flange engages an edge of the top plate which moves the part toward an edge of the lower plate such that the part falls off the lower plate.
40. The apparatus of claim 37 wherein the gauge has a plate with an ejector which engages a portion of the parts when the parts are incorrectly orientated and removes the parts from the channel.
41. The apparatus of claim 37 wherein the gauge has a plate with an opening wherein when the parts have the incorrect orientation the parts fall through the opening in the plate.
42. The apparatus of claim 37 wherein a level sensor is provided in the bin for activating and deactivating a feed means based on an amount of parts in the bin.
43. The apparatus of claim 37 wherein an air jet is mounted adjacent the opening in the bin for assisting a movement of the parts through the opening.
44. A method for sorting and orientating parts, which comprises:
(a) a vibrating bin having an open top and a closed bottom with a sidewall extending therebetween having an inner surface, the sidewall having an opening adjacent the open top of the bin; a channel means mounted on the inner surface of the bin for moving the parts in a row from the bottom of the bin toward the top of the bin; and a gauge means mounted in the channel for removing the parts from the channel which have an incorrect orientation wherein the bin vibrates such as to move the parts along the channel from the bottom of the bin toward the opening in the sidewall of the bin and wherein the gauge acts to engage the parts such that parts having an incorrect orientation are removed from the channel and deposited back toward the bottom of the bin;
(b) feeding the parts into the bin; and
(c) activating the bin such that the bin vibrates and moves the parts along the channel wherein as the parts move along the channel the parts move across the gauge which removes parts having the incorrect orientation from the channel and wherein parts having an incorrect orientation are moved out of the bin through the opening in the sidewall of the bin.
45. An apparatus for feeding parts at a predetermined rate, which comprises:
(a) a housing having opposed open ends with a bore extending therebetween along a longitudinal axis of the apparatus;
(b) a first piston means mounted between the ends of the housing such as to extend perpendicular to the longitudinal axis of the housing wherein when the first piston means is extended, the first piston means extends into the channel; and
(c) a second piston means mounted between the ends of the housing adjacent to and spaced apart from the first piston means such as to extend perpendicular to the longitudinal axis of the housing wherein when the second piston means is extended the second piston means extends into the channel.
46. The apparatus of claim 45 wherein an air jet is mounted between the ends of the housing such as to direct a stream of air into the channel adjacent the second piston means and wherein the stream of air assists in moving the parts along the channel and out of the apparatus.
47. The apparatus of claim 46 wherein the air jet is angled in a direction of movement of the parts.
48. The apparatus of claim 46 wherein the air jet is located on a side of the channel opposite the first piston means.
49. The apparatus of claim 45 wherein the first and second piston means are activated by air.
50. The apparatus of claim 45 wherein the second piston means has a force such as to hold the parts in the channel without damaging the parts.
51. The apparatus of claim 45 wherein a distance between the first and second piston means is approximately equal to a length of the parts such that when the first and second piston means are extended, a part is located between the first and second piston means and without contacting the first or second piston means.
52. The apparatus of claim 45 wherein when the second piston means has a shape similar to a shape of the parts.
53. A method for separating and feeding parts at a predetermined rate, which comprises the steps of:
(a) providing a housing having opposed open ends with a bore extending therebetween along a longitudinal axis of the apparatus; a first piston means mounted between the ends of the housing such as to extend perpendicular to the longitudinal axis of the housing wherein when the first piston means is extended, the first piston means extends into the channel; and a second piston means mounted between the ends of the housing adjacent to and spaced apart from the first piston means such as to extend perpendicular to the longitudinal axis of the housing wherein when the second piston means is extended the second piston means extends into the channel;
(b) activating the first piston means such that the first piston extends into the channel and prevents the parts from moving beyond the first piston means in the channel;
(c) feeding a row of parts into the channel of the housing through one open end;
(d) activating the second piston means such as to extend the second piston means into the channel such that a first part is located between the first and second piston means and wherein the second piston means contacts a second part in the channel and holds the second part in place in the channel;
(e) deactivating the first piston means such that the first piston means moves out of the channel and the first part between the first and second piston means moves along the channel and out of the apparatus;
(f) activating the first piston means such that the first piston means extends into the channel and prevents the parts from moving beyond the second piston means in the channel; and
(g) deactivating the second piston means such that the second part is released and moved toward the first piston means and is located between the first and second piston means.
54. The method of claim 53 wherein an air jet is mounted in the housing such as to provide a stream of air into the channel of the housing wherein the air jet is activated at the same time as the first piston means is deactivated such that the stream of air assists in moving the part out of the housing.
55. The method of claim 53 wherein the parts move through the housing at a rate of between about 5 and 50 parts per minute.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US09/970,255 US6443291B2 (en) | 1998-06-30 | 2001-10-03 | Method and apparatus for providing parts to workpieces |
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US09/109,296 US6102193A (en) | 1998-06-30 | 1998-06-30 | Method and apparatus for providing parts to workpieces |
US09/621,799 US6298977B1 (en) | 1998-06-30 | 2000-07-21 | Method and apparatus for providing parts to workpieces |
US09/970,255 US6443291B2 (en) | 1998-06-30 | 2001-10-03 | Method and apparatus for providing parts to workpieces |
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US09/621,799 Division US6298977B1 (en) | 1998-06-30 | 2000-07-21 | Method and apparatus for providing parts to workpieces |
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US09/621,799 Expired - Fee Related US6298977B1 (en) | 1998-06-30 | 2000-07-21 | Method and apparatus for providing parts to workpieces |
US09/970,255 Expired - Fee Related US6443291B2 (en) | 1998-06-30 | 2001-10-03 | Method and apparatus for providing parts to workpieces |
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US09/109,296 Expired - Fee Related US6102193A (en) | 1998-06-30 | 1998-06-30 | Method and apparatus for providing parts to workpieces |
US09/621,799 Expired - Fee Related US6298977B1 (en) | 1998-06-30 | 2000-07-21 | Method and apparatus for providing parts to workpieces |
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US6443291B2 (en) * | 1998-06-30 | 2002-09-03 | Ernest M. Rivers, Jr. | Method and apparatus for providing parts to workpieces |
US20060184282A1 (en) * | 2002-09-26 | 2006-08-17 | Hagen Strasser | Gripping device for manipulating device and method for operation thereof |
US20190080579A1 (en) * | 2017-09-08 | 2019-03-14 | Tyco Fire & Security Gmbh | Chamberless Smoke Detector |
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JP4185635B2 (en) * | 1999-09-24 | 2008-11-26 | セキ工業株式会社 | Nut feeder for nut resistance welding |
US6790412B2 (en) * | 2001-02-06 | 2004-09-14 | Beckman Coulter, Inc. | Bulk vessel feeder |
FI116280B (en) * | 2003-05-05 | 2005-10-31 | Wisematic Oy | Feeder for small parts |
US6945384B2 (en) * | 2003-10-30 | 2005-09-20 | Seki Kogyo Co., Ltd. | Parts aligner |
JP4147554B2 (en) * | 2004-02-14 | 2008-09-10 | 好高 青山 | Positioning device for component feeder |
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1998
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-
2000
- 2000-07-21 US US09/621,799 patent/US6298977B1/en not_active Expired - Fee Related
-
2001
- 2001-10-03 US US09/970,255 patent/US6443291B2/en not_active Expired - Fee Related
Cited By (5)
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US6443291B2 (en) * | 1998-06-30 | 2002-09-03 | Ernest M. Rivers, Jr. | Method and apparatus for providing parts to workpieces |
US20060184282A1 (en) * | 2002-09-26 | 2006-08-17 | Hagen Strasser | Gripping device for manipulating device and method for operation thereof |
US7792609B2 (en) * | 2002-09-26 | 2010-09-07 | Trumpf Maschinen Austria Gmbh & Co. Kg. | Gripping device for manipulating device and method for operation thereof |
US20190080579A1 (en) * | 2017-09-08 | 2019-03-14 | Tyco Fire & Security Gmbh | Chamberless Smoke Detector |
EP4151564A1 (en) | 2021-09-17 | 2023-03-22 | Ohrmann Montagetechnik GmbH | Vibrating helical conveyor and sealing ring separation assembly |
Also Published As
Publication number | Publication date |
---|---|
US6443291B2 (en) | 2002-09-03 |
US6298977B1 (en) | 2001-10-09 |
US6102193A (en) | 2000-08-15 |
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