US 11,989,875 B2Granted

Automated manufacturing cell

OwnerSteve Tomkiewicz, Kurt Behrendt +1inventors

InventorsSteve Tomkiewicz, Kurt Behrendt, Kevin Desotell

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Abstract

Disclosed herein are systems and methods for efficiently and economically manufacturing molded polymer products such as those that require a two-shot, two-material injection molding process, with complex geometries and incorporate metal components such as inserts. The systems and methods include compact manufacturing cells and processes of operating such manufacturing cells. The manufacturing cells include a single injection molding machine with two molds arranged to simultaneously operate both molds. The manufacturing cell is arranged to be fully automated so that it is operative without the need for intervention or management from dedicated personnel. Such automation includes the automated sorting and placement of metal inserts into the injection molding machine, the automated removal of the product after the first molding stage and second molding stage, the automated inspection of every finished product, the automated sorting of conforming and rejected products, and the automated packaging of finished product for shipment to end user.

Claims9

Dependent claims

A method of inspecting a manufactured component comprising the following steps:

positioning a component for inspection;
initiating a first flash of light and directing said first flash of light toward the component;
capturing a first image of the component with one of a plurality of cameras during the first flash of light;
analyzing the image of the component and determining if the component is positioned at a location where an inspection can be conducted;
if the component is not in a location where an inspection can be conducted, the component is moved to a position where the inspection can be conducted;
initiating a second flash of light and directing said second flash of light toward the component;
capturing a second image of the component with one of a plurality of cameras during the second flash of light;
comparing the second image to stored information to determine if the component is geometrically fully formed;
analyzing the second image to determine if one or more inserts are present in the component;
initiating a third flash of light and directing said third flash of light toward the component;
capturing a third image of the component with one of a plurality of cameras during the third flash of light;
comparing the third image to stored information to determine if the component is geometrically fully formed;
determining if the component meets a specification for the component;
directing the component to a first location if it is determined that the component does not meets the specification for the component;
and
directing the component to a second location if it is determined that the component does meet the specification for the component.

13 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/662,386Filed 6 May 2022 · us provisional application
Priority: 6 May 2021
Published: US 2022/0358629 A110 Nov 2022
Granted: 21 May 2024
Term ends: Not estimatedThe source records don’t support an estimate.

Classification20 codes

G06T 7/001
Industrial image inspection: using an image reference approach
B29C 45/14008
Incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles: inserting articles into the mould
B29C 45/76
Component parts, details or accessories; Auxiliary operations: measuring, controlling or regulating
G01B 11/245
For measuring contours or curvatures: using a plurality of fixed, simultaneously operating transducers