US 4,815,190 A · Method for automated assembly of assemblies such as automotive assemblies

Abstract

Method and system for the automated assembly of power train components along a plurality of interconnected, closed loops within cells of the system wherein parts and/or subassemblies of the components are assembled on the same assembly pallet on which they were robotically kitted. Along some of the loops, the assembly pallets are automatically transferred from kitting stations to assembly stations and from the assembly stations to an unload station where the components or subassemblies are robotically unloaded. The unloaded assembly pallets are then automatically transferred from the unload station to the kitting stations to repeat the assembly process. A mechanical guided vehicle system (MGVS) asynchronously conveys the assembly pallets along the closed loops which form guide tracks between the different stations. An automated guided vehicle system (AGVS) preferably transports part storage pallets to the system from a receiving area. Automated stacking cranes transfer the part storage pallets to and from predetermined part positions within queuing rack structures adjacent the kitting and assembly stations. The queuing rack structures and the automatic stacking cranes form part of an automated storage and retrieval system (AS/RS) which interconnect the different closed loop guide tracks. The queuing rack structure also stores subassemblies loaded on assembly pallets. Manual kitting and assembly areas are also provided. Fastening robots are provided at fastening stations located along selected ones of the guide tracks. A distributed or hierarchial control system controls each of the elements of the system. When finally assembled, the power train components are robotically unloaded from their assembly pallets and transported by the AGVS to a vehicle assembly area.

Claims30

Dependent claims

A method for the automated assembly of parts on an assembly pallet in an assembly area, the method comprising:

(a) automatically transferring the assembly pallet to a knitting station in the assembly area including a kitting robot having a work envelope;
(b) storing a first set of parts at the kitting station within the work envelope of the kitting robot;
(c) utilizing the kitting robot to pick and place the first set of the parts on the assembly pallet at a first set of predetermined positions thereon;
(d) automatically transferring the assembly pallet loaded with the parts to an assembly station in the assembly area to assemble the parts on the assembly pallet into at least one assembly;
(e) automatically transferring the assembly on the assembly pallet to an unload station for unloading the assembly from the assembly pallet wherein the assembly area includes first and second kitting stations including first and second kitting robots, respectively, each of the kitting robots having a work envelope and wherein the method further comprising the steps of:
(f) storing a second set of the parts at the second kitting station within the work envelope;
(g) automatically transferring the assembly pallet from the first kitting station to the second kitting station;
(h) utilizing the second kitting robot to pick and place the second set of the parts on the assembly pallet at a second set of predetermined positions thereon;
(i) automatically monitoring and coordinating operation of the first and second kitting robots with the automatic transferring of the assembly pallet to and from the kitting stations to control the flow of parts and the pallet in the assembly area;
and
repeating steps (a) through (i) for each assembly.

8 more elements

A method for the automated assembly of parts and at least one subassembly on an assembly pallet in an assembly area, the method comprising:

(a) automatically transferring the assembly pallet to a kitting station in the assembly area including at least one kitting robot having a work envelope;
(b) storing a first set of parts and the subassembly at the kitting station within the work envelope of the kitting robot;
(c) utilizing the kitting robot to pick and place a first set of the parts on the assembly pallet at a first set of predetermined positions thereon and to pick and place the subassembly on the assembly pallet at a second predetermined positions thereon;
(d) automatically transferring the assembly pallet loaded with the parts to an assembly station in the assembly area to assemble the parts and the subassembly on the assembly pallet into at least one assembly;
(e) automatically transferring the assembly on the assembly pallet to an unload station for unloading the assembly from the assembly pallet wherein the assembly area includes first and second kiting stations including first and second kitting robots, respectively, each of the kitting robots having a work envelope and wherein the method further comprises the steps of:
(f) storing a second set of the parts at the second kitting station within the work envelope of the second kitting robot;
(g) automatically transferring the assembly pallet from the first kitting station to the second kitting station;
(h) utilizing the second kitting robot to pick and place the second set of the parts on the assembly pallet at a second set of predetermined positions thereon;
(i) automatically monitoring and coordinating operation of the first and second kitting robots with the automatic transferring of the assembly pallet to and from the kitting stations to control the flow of parts and the pallet in the assembly area;
and
repeating steps (a) through (i) for each assembly.

8 more elements

A method for the automated assembly of parts and a subassembly on an assembly pallet in an assembly area, the method comprising:

(a) automatically transferring a first assembly pallet to a first kitting station in the assembly area including a first kitting robot having a work envelope;
(b) storing a first set of parts at the first kitting station within the work envelope of the first kitting robot;
(c) utilizing the first kitting robot to pick and place the first set of the parts on the first assembly pallet at a first set of predetermined positions thereon;
(d) automatically transferring the first assembly pallet loaded with the parts to a first assembly station in the assembly area to assemble the parts on the assembly pallet into at least one subassembly;
(e) automatically transferring the subassembly on the first assembly pallet to a first unload station;
(f) unloading the subassembly from the first assembly pallet at the first unload station;
(g) storing the subassembly at a predetermined subassembly position in a storage area;
(h) storing a second set of the parts at predetermined part positions within the storage area;
(i) automatically transferring a second assembly pallet to a second kitting station in the assembly area including a second kitting robot having a work envelope;
(j) automatically transferring the second set of parts and the subassembly from the storage area to the second kitting station within the work envelope of the second kitting robot;
(k) utilizing the second kiting robot to pick and place the second set of parts and the subassembly on the second assembly pallet at a second set of predetermined positions thereon;
(l) automatically transferring the second assembly pallet loaded with the second set of parts and the subassembly to a second assembly station in the assembly area to assemble the parts and the subassembly on the second assembly pallet into an assembly;
(m) automatically transferring the assembly on the second assembly pallet to a second unload station for unloading the assembly from the second assembly pallet;
(n) automatically monitoring and coordinating operation of the first and second kitting robots with the automatic transferring of the assembly pallet to and from the kitting stations to control the flow of parts and the pallet in the assembly area;
and
repeating steps (a) through (n) for each assembly.

13 more elements

A method for the automated assembly of parts and first and second subassemblies on an assembly pallet in an assembly area, the method comprising:

(a) automatically transferring a first assembly pallet to a first kitting station in the assembly area including a first kitting robot having a working envelope;
(b) storing a first set of parts at the first kitting station within the work envelope of the first kitting robot;
(c) utilizing the first kitting robot to pick and place the first set of the parts on the first assembly pallet at a first set of predetermined positions thereon;
(d) automatically transferring the first assembly pallet loaded with the parts of a first assembly station in the assembly area to assemble the parts on the assembly pallet into a first subassembly;
(e) automatically transferring the first subassembly on the first assembly pallet to a first unload station;
(f) unloading the first subassembly from the first assembly pallet at the first unload station;
(g) storing the first subassembly at a first predetermined subassembly position in a first storage area;
(h) storing a second set of the parts at predetermined part positions and a second subassembly at a second predetermined subassembly position within the first storage area;
(i) automatically transferring a second assembly pallet to a second kitting station in the assembly area including a second kitting robot having a work envelope;
(j) automatically transferring the second set of parts and the first subassembly from the storage area to the second kitting station within the work envelope of the second kitting robot;
(k) utilizing the second kiting robot to pick and place the second set of parts and the first subassembly on the second set of parts and the first subassembly on the second assembly pallet at a second set of predetermined positions thereon;
(l) automatically transferring the second assembly pallet from the second kitting station to a third kitting station in the assembly area including a third kitting robot having a work envelope;
(m) automatically transferring the second subassembly from the first storage area to the third kitting station within the work envelope of the third kitting robot;
(n) utilizing the third kitting robot to pick and place the second subassembly on the second assembly pallet at a predetermined position thereon;
(o) automatically transferring the second assembly pallet loaded with the second set of parts and the first and second subassemblies to a second assembly station in the assembly area to assemble the parts and the first and second subassemblies on the second assembly pallet into an assembly;
(p) automatically transferring the assembly on the second assembly pallet to a second unload station for unloading the assembly from the second assembly pallet;
(q) automatically monitoring and coordinating operation of the first and second kitting robots with the automatic transferring of the assembly pallet to and from the kitting stations to control, the flow of parts and the pallet in the assembly area;
and
repeating steps (a) through (q) for each assembly.

16 more elements

Dependencies are inferred from the claim text.

Method for automated assembly of assemblies such as automotive assemblies

Life of this patent

Method for automated assembly of assemblies such as automotive assemblies

Life of this patent

Abstract

Claims30