# US 8,229,586 B2 · Method and apparatus for assembling a complex product in a parallel process system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,229,586 B2 - Document ID: US8229586B2 - Status: Granted - Kind: B2 - Application number: 12/102,046 - Filed: 2008-04-14 - Published: 2009-05-07 - Granted: 2012-07-24 - Earliest claimed: 2007-12-12 - Assignees: Comau S.p.A. - Inventors: Richard A. Wallace; John Graham; Theodore Robert Brown - Web page: https://patentgrep.com/patent/US8229586B2 ## CPC - G05B 19/418: Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] - B23P 19/001: {Article feeders for assembling machines (screws or nuts being carried by a disposable strip or disc B25B23/045)} - B23P 19/042: {specially adapted for combustion engines (shape of casings adapted to facilitate fitting or dismantling of engine parts for combustion engines F02F7/0046)} - B23P 21/00: Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with program control - B23P 21/002: {the units stationary whilst being composed} - B23P 23/04: for both machining and other metal-working operations - G05B 19/41805: {characterised by assembly} - B23P 2700/50: Other automobile vehicle parts, i.e. manufactured in assembly lines - G05B 2219/31054: Planning, layout of assembly system - Y02P 90/02: Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS] - G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G) - B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q) - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A method and apparatus for assembling a complex product in a parallel process system wherein a collection of components are provided for assembling the complex product. The present invention involves transferring the collection of the components to one of a plurality of similar computerized assembly cells through the use of a transport system. The collection of components is automatically assembled into the complex product through the use of the computerized assembly cells. The complex product is then transferred from one of the assembly cells to a computerized test cell, where the complex product is tested to ensure for the proper dimensioning and functioning of the complex product. The complex product is then transferred from the test cell via the transport system to either a part reject area or conveyor, if the complex product is defective, or to an automatic dunnage load or part return system, if the complex product is not defective. ## Claims ### Claim 1 A method for assembling a complex product in a parallel process system, the steps comprising: providing a collection of sub-components and at least one base component to a loading station for assembling said complex product; automatically transporting said collection of sub-components and said at least one base component to one of at least one similar computerized assembly cells through the use of a transport system; automatically assembling said collection of sub-components and said base component into said complex product through the use of said at least one computerized assembly cell; automatically transporting said complex product to a delivery station through the use of said transport system; automatically transporting said complex product from said at least one assembly cell to one of at least one similar computerized test cells through the use of said transport system; and automatically testing said complex product in said at least one computerized test cell to ensure for the proper assembly functionality of said complex product. ### Claim 2 (depends on 1) The method as stated in claim 1, wherein said step of providing a collection of sub-components and at least one base component further comprise the steps of: manually loading said sub-components and said at least one base component into said transport system. ### Claim 3 (depends on 1) The method as stated in claim 1, wherein said step of providing a collection of sub-components and at least one base component further comprise the steps of: providing a part delivery system for supplying said at least one base component to said transport system; and providing a kit delivery system for supplying said sub-components in a kit container to said transport system. ### Claim 4 (depends on 3) The method as stated in claim 3, wherein said step of providing a part delivery system further comprises the steps of: providing a conveyor for delivering said at least one base component to said transport system. ### Claim 5 (depends on 4) The method as stated in claim 4, wherein said step of providing a kit delivery system for supplying said sub-components in a kit container further comprises the steps of: automatically assembling said sub-components into said kit container through the use of at least one kit assembly cell; and providing a conveyor for delivering said kit container to said transport system. ### Claim 6 (depends on 3) The method as stated in claim 3, wherein said step of providing a part delivery system further comprises the steps of: providing a conveyor for delivering said kit container with said sub-components assembled therein to said transport system. ### Claim 7 (depends on 3) The method as stated in claim 3, wherein said step of transporting said collection of said sub-components and said at least one base component further comprise the steps of: providing an overhead gantry system for transporting said kit container, said at least one base component, and said complex product to and from said loading station, said plurality of assembly cells, said at least one test cell, and said delivery station. ### Claim 8 (depends on 3) The method as stated in claim 3, wherein said step of transferring said collection of said sub-components and said at least one base component further comprises the steps of: providing a computerized robotic arm for automatically transporting said kit container, said at least one base component, and said complex product to and from said loading station, said plurality of assembly cells, said at least one test cell, and said delivery station. ### Claim 9 (depends on 3) The method stated in claim 3, further comprising the steps of: securing said at least one base component in a rollover fixture in one of said plurality of computerized assembly cells for rotating said at least one base component in a desired orientation; and placing said kit container within one of said plurality of computerized assembly cells. ### Claim 10 (depends on 1) The method stated in claim 1, further comprising the steps of: providing a computerized tool changer in each of said computerized assembly cells for automatically providing an appropriate tool for assembling said sub-components to said at least one base component for forming said complex product; and providing three axes of linear movement between said at least one base component and said appropriate tool. ### Claim 11 (depends on 1) The method stated in claim 1, further comprising the steps of: securing said complex product in a rollover fixture in said at least one computerized test cell for rotating said complex product an a desired orientation; providing a computerized test tool changer in each of said at least one test cell for automatically providing an appropriate test tool for testing said complex product; and providing three axes of linear movement between said complex product and said appropriate test tool. ### Claim 12 An apparatus for assembling a complex product in a parallel process system comprising: a loading station for providing a collection of sub-components and at least one base component required for assembling said complex product; a plurality of computerized assembly cells for automatically assembling said sub-components to said base components to form said complex product; a delivery station for receiving said complex product after said complex product is assembled; a transport system for transporting said sub-components, said at least one base component, and said complex products to and from said loading station, said plurality of assembly cells, and said delivery station; and at least one computerized test cell for automatically testing said complex product to test for the proper assembly functionality of said complex product. ### Claim 13 (depends on 12) The apparatus stated in claim 12, wherein said loading station further comprise: manually loading said sub-components and said base component into said transport systems. ### Claim 14 (depends on 12) The apparatus as stated in claim 12, wherein said loading station further comprises: a part delivery system for delivering said at least base component to said transport system; and a kit delivery system for delivering a kit container having said sub-components contained therein to said transport system. ### Claim 15 (depends on 12) The apparatus as stated in claim 12, wherein said part delivery system further comprises: a conveyor for delivering said at least one base component to said transport system. ### Claim 16 (depends on 12) The apparatus as stated in claim 12, wherein said kit delivery system further comprises: a conveyor for delivering said kit container to said transport system. ### Claim 17 (depends on 12) The apparatus as stated in claim 12, wherein said kit delivery system further comprises: an automatic kit assembly cell for receiving and assembling said sub-components into said kit container; and a conveyor for delivering said kit container to said transport system. ### Claim 18 (depends on 12) The apparatus as stated in claim 12, wherein said transport system further comprises: a computerized overhead gantry system for automatically picking and placing said kit container, said at least one base component, and said complex product to and from said loading station, said computerized assembly cells, said at least one computerized test cell, and said delivery station. ### Claim 19 (depends on 18) The apparatus as stated in claim 18, further comprising: a carriage having said rollover fixture and kit container fixture connected thereto; and a pair of rails for slidably receiving said carriage, and said rails extending to and from said assembly cell wherein said carriage moves between an unloaded position, wherein said carriage is outside said assembly cell, and a loaded position, wherein said carriage is within said assembly cell. ### Claim 20 (depends on 12) The apparatus as stated in claim 12, wherein said transport system further comprises: a computerized robotic arm for automatically picking and placing said kit container, said at least one base component, and said complex product to and from said loading station, said automatic assembly cell, said at least once automatic test cell, and said delivery station. ### Claim 21 (depends on 12) The apparatus as stated in claim 12, wherein each of said computerized assembly cells further comprise: a roll-over fixture mounted within each of said assembly cells for securing and rotating said at least one base component in a desired orientation for assembling said sub-components thereto; a kit container fixture within each of said computerized assembly cells for receiving said kit container; a computerized tool changer within each of said assembly cells for automatically providing an appropriate tool for assembling said sub-components in said kit container to said at least one base component; and said roll-over fixture and said computerized tool changer moveable with respect to one another in three axes of linear motion. ### Claim 22 (depends on 12) The apparatus as stated in claim 12, wherein each of said at least one computerized test cell further comprises: a roll-over fixture mounted within each of said at least one automatic test cell for securing and rotating said complex product in a desired orientation for testing said complex product; a computerized tool changer within said at least one test cell for automatically providing an appropriate test tool for testing said complex product; and said roll-over fixture and said appropriate test tool moveable with respect to one another in three axes of linear movement. ### Claim 23 (depends on 12) The apparatus as stated in claim 12, wherein said delivery station further comprises: a first area within said delivery station for receiving said complex products that are defective; and a second area within said delivery station for receiving said complex products that are non-defective.