Systems with robotic arms for handling and milling a workpiece, and for positioning a vacuum pod on a milling platform

A system for processing a plurality of workpieces from an input staging area to an output staging area, the system comprising:

• a plurality of carrier members, wherein each of the carrier members is sized and shaped to support one of the workpieces, and wherein the carrier members are moveable independently of each other;
• a conveyor device comprising at least one roller conveyor, belt conveyor, chain conveyor or a combination thereof, wherein the conveyor device comprises:
• a conveyor main path extending from an input station to an output station;
• a pre-milling station branching from the conveyor main path;
• and a milling station branching from the conveyor main path;
• wherein the conveyor device is operable to move each one of the carrier members, independently of each other, along:
• a first conveyor route from the input station via to conveyor main path to the pre-milling station;
• a second conveyor route from the pre-milling station to the milling station;
• a third conveyor route from the milling station via the conveyor main path to the output station;
• and
• a fourth conveyor route from the output station via the conveyor main path to the input station;
• and
• an input workpiece handling robotic arm (input WHRA) and an output workpiece handling robotic arm (output WHRA), wherein the input WHRA is adapted to move one of the workpieces from the input staging area to one of the carrier members disposed at the input station, and wherein the output WHRA is adapted to move one of the workpieces from one of the carrier members disposed at the output station to the output staging area;
• and
• a spindle robotic arm (SRA) comprising a milling tool, wherein the SRA is adapted to mill one of the workpieces when supported on one of the carrier members disposed at the milling station.

A system for positioning a plurality of vacuum pods on a carrier member to support a workpiece, the system comprising:

• a robotic arm (RA) comprising an end effector to attach to the vacuum pods;
• a processor operatively connected to the RA, and configured by a memory comprising a non-transitory computer readable medium storing instructions executable by the processor to implement a method comprising:
• looking up a set of positions, stored in the memory, for placing the vacuum pods on the carrier member to support the workpiece based on an identifier or a geometry of the workpiece;
• and
• controlling the RA to place the vacuum pods at the set of positions on the carrier member.

A system for handling a workpiece, the system comprising:

• a carrier member;
• at least one vacuum pod disposed on the carrier member for supporting the workpiece, and comprising a sealing surface defining a vacuum aperture to apply suction to the workpiece and in fluid communication with a vacuum conduit;
• a vacuum generator comprising a vacuum pump or a vacuum blower, and defining a vacuum inlet;
• and
• a conveyor device comprising one or a combination of a roller conveyor, a belt conveyor and a chain conveyor, wherein the conveyor device is operable to move the carrier member to a station and thereby connect the vacuum conduit with the vacuum inlet to establish fluid communication between the vacuum aperture and the vacuum inlet.

A system for positioning a vacuum pod movable relative to a milling platform, the system comprising:

• a robotic arm (RA) comprising a suction surface to sealingly engage the vacuum pod such that movement of the suction surface causes the vacuum pod to move in unison with the suction surface;
• and
• a processor operatively connected to the RA, and configured by a non-transitory computer readable medium storing instructions executable by the processor to implement a method comprising:
• controlling the RA to move the suction surface into sealing engagement with the vacuum pod at a first position on the milling platform;
• controlling the RA to move the suction surface with the vacuum pod sealingly engaged thereto from the first position to a second position on the milling platform;
• and
• controlling the RA to disengage the suction surface from the vacuum pod at the second position on the milling platform.

A system for controlling a workpiece handling robotic arm (WHRA) comprising a holding tool to release a workpiece on a milling platform, the system comprising:

• a plurality of contact position sensors, wherein each of the plurality of contact position sensors comprises a probe actuable to engage the workpiece, wherein different ones of the probes engage the workpiece at different workpiece locations, and wherein the plurality of the contact position sensors are configured to collectively generate positional data indicative of a position of the workpiece in at least a two-dimensional plane;
• and
• a processor operatively connected to the plurality of contact position sensors and the WHRA, and configured by a non-transitory computer readable medium storing instructions executable by the processor to implement a method comprising:
• actuating probes of the plurality of contact position sensors to engage the workpiece and generate the positional data;
• and
• controlling the WHRA to move the holding tool to a release position for releasing the workpiece on the milling platform, wherein the release position is based at least on the positional data.