Patents by Inventor Kenneth Wayne NICHOLSON
Kenneth Wayne NICHOLSON has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 12344483Abstract: A conveyor system and method for controlling the same. The conveyor system includes: at least one moving element; a track including: a straight track section with a first mechanism for moving the moving element; and a curved track section connected to the straight track section including a second mechanism for moving the moving element; and a controller configured to control a speed of the moving element as the moving element moves from the straight track section to the curved track section and vice versa such that a velocity profile of the moving element includes a sinusoidal portion to provide a transition from straight to rotary motion or from rotary to straight motion having a linear position profile. In the method, the controller controls at least one of the first mechanism and the second mechanism to move the moving element according to the velocity profile including the sinusoidal portion.Type: GrantFiled: February 3, 2023Date of Patent: July 1, 2025Assignee: ATS CORPORATIONInventors: Roger Hogan, Blake Robert Lambert, Anton Dolgovykh, Braden Jon Guenther, Philip David Munroe, Albert John Kleinikkink, Kenneth Wayne Nicholson
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Publication number: 20250205973Abstract: A method of ultrasonic welding in an automated mass production process includes: (a) advancing a pallet to move a set of workpieces in the pallet into alignment with a lift of an ultrasonic welding station; (b) operating the lift to raise the set of workpieces out from the pallet and into contact with a horn of the ultrasonic welding station; (c) when the set of workpieces are in contact with the horn, transmitting vibrational energy from the horn to the set of workpieces to weld the workpieces together in a welding operation; and (d), after (c), operating the lift to lower the set of workpieces out of contact with the horn and back into the pallet.Type: ApplicationFiled: March 7, 2025Publication date: June 26, 2025Inventors: Kenneth Wayne NICHOLSON, Philip David MUNROE
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Publication number: 20250197130Abstract: A method of processing workpieces in an automated mass production system includes: (a) receiving a supply carrier at a workpiece repitch station, the supply carrier including a plurality of rows of supply retainers, each supply retainer holding a respective workpiece for unloading at the repitch station; (b) advancing a plurality of processing carriers through the repitch station, each processing carrier including a row of processing retainers for receiving respective workpieces unloaded from the supply carrier; (c) operating a repitch robot at the repitch station to repitch and transfer a set of workpieces from respective supply retainers to the respective processing retainers of a respective processing carrier at the repitch station; and (d) repeating the operating step to fill each of the plurality of processing carriers advanced through the repitch station with workpieces from the supply carrier.Type: ApplicationFiled: February 28, 2025Publication date: June 19, 2025Inventors: Kenneth Wayne NICHOLSON, David Andrew TAIT, Robert James MACGREGOR
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Patent number: 12330884Abstract: A method of inverting workpieces in a mass production process includes: advancing an end effector in electronic synchronization with advancement of a carrier to synchronize arrival of the carrier at a stop position with arrival of the end effector at an unloading position, in which the end effector is in alignment with a workpiece held by the carrier for engaging the workpiece; while the end effector is in engagement with the workpiece, retracting the end effector away from the carrier to unload the workpiece from the carrier and advancing the end effector back toward the carrier to load the workpiece back into the carrier; and rotating the end effector relative to the carrier to invert the workpiece in electronic synchronization with the retracting and advancing of the end effector for loading the workpiece back into the carrier when inverted.Type: GrantFiled: March 18, 2024Date of Patent: June 17, 2025Assignee: ATS CORPORATIONInventors: Kenneth Wayne Nicholson, Philip David Munroe, James Mark McLean, Robert James MacGregor, David Andrew Tait, Gustavo Barea, Roger Craig Hogan
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Publication number: 20250187195Abstract: An O-ring processing station for an automated mass production system includes: (a) at least one feed device operable to control discharge of O-rings from an output end of the feed device; (b) an indexing device having a plurality of O-ring retainers, the indexing device operable to advance each retainer to a loading position in alignment with the output end for receiving an O-ring from the feed device, and an unloading position spaced apart from the loading position for unloading the O-ring from the retainer; and (c) a pick-and-place robot including at least one end effector movable between a pick-up position in alignment with a retainer at the unloading position for removing the O-ring from the retainer, and a drop-off position spaced apart from the pick-up position for installation of the O-ring onto a workpiece.Type: ApplicationFiled: February 19, 2025Publication date: June 12, 2025Inventors: Kenneth Wayne Nicholson, Philip David MUNROE, James Mark MCLEAN, Robert James MACGREGOR, David Andrew TAIT, Gustavo BAREA, Roger Craig HOGAN
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Patent number: 12264016Abstract: A method of repitching workpieces in an automated mass production system includes: (a) unloading a set of workpieces from a plurality of first retainers arranged at a first pitch, the unloading step including gripping of the workpieces by corresponding grippers of a repitch robot; (b) adjusting the workpieces from the first pitch to a second pitch different from the first pitch, the adjusting step including translating the grippers relative to each other from a first spacing corresponding to the first pitch to a second spacing corresponding to the second pitch; and (c) loading the workpieces into a plurality of corresponding second retainers arranged at the second pitch, the loading step including positioning and releasing the workpieces in the second retainers via the grippers.Type: GrantFiled: September 6, 2022Date of Patent: April 1, 2025Assignee: ATS CorporationInventors: Kenneth Wayne Nicholson, David Andrew Tait, Robert James MacGregor
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Patent number: 12257724Abstract: Processing O-rings in an automated mass production system includes advancing an O-ring retainer toward a loading position in alignment with an output end of a feed device, discharging a leading O-ring from the output end in electronic synchronization with advancement of the O-ring retainer to the loading position to initiate loading of the O-ring into the retainer prior to the retainer arriving at the loading position, after loading the O-ring into the retainer, advancing the retainer away from the loading position toward an unloading position, and moving an end effector in electronic synchronization with advancement of the retainer to the unloading position to synchronize arrival of the retainer at the unloading position with arrival of the end effector at a pick-up position in alignment with the O-ring at the unloading position for pick up of the O-ring by the end effector.Type: GrantFiled: March 17, 2022Date of Patent: March 25, 2025Assignee: ATS CORPORATIONInventors: Kenneth Wayne Nicholson, Philip David Munroe, James Mark McLean, Robert James MacGregor, David Andrew Tait, Gustavo Barea, Roger Craig Hogan
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Publication number: 20250021080Abstract: An automated mass production process including: (a) advancing a supply carrier toward a stop position adjacent a syringe insertion station, the supply carrier holding a pre-filled syringe and the syringe insertion station including an arm, a receiving port and a driver; (b) aligning a vertical axis of the driver of the syringe insertion station with a vertical axis of the receiving port of the syringe insertion station; (c) advancing an injector body toward the receiving port in synchronization with the supply carrier to the stop position; (d) moving, by the arm, the pre-filled syringe from the supply carrier to the vertical axis of the receiving port of the syringe insertion station; (e) applying a downward force by the driver along the vertical axis to direct the pre-filled syringe into the injector body; (f) retracting the arm and the driver from the pre-filled syringe.Type: ApplicationFiled: September 25, 2024Publication date: January 16, 2025Inventors: Kenneth Wayne NICHOLSON, Philip David MUNROE, Ryan David CHUBB, Philip Michael KURTZ, Michael Tze-Chun CHOW
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Publication number: 20240369996Abstract: Various systems and methods for maintaining a record for a workpiece processed by a CNC electronically synchronized cell of a manufacturing assembly line are disclosed herein. Example embodiments involve a cell controller and a part-processing control system. The cell controller can be configured to: initialize a cell controller record; initiate a part assembly task involving at least one electronically synchronized part-processing operation and upon completion of each operation, update an inspection identifier of the cell controller.Type: ApplicationFiled: July 18, 2024Publication date: November 7, 2024Inventors: Chad William COLYER, Robert David ALMAS, Philip David MUNROE, James Mark MCLEAN, Connor Hugh MCINTOSH MURRAY, Hang TRAN, Kenneth Wayne NICHOLSON
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Publication number: 20240308783Abstract: A method of inverting workpieces in a mass production process includes: advancing an end effector in electronic synchronization with advancement of a carrier to synchronize arrival of the carrier at a stop position with arrival of the end effector at an unloading position, in which the end effector is in alignment with a workpiece held by the carrier for engaging the workpiece; while the end effector is in engagement with the workpiece, retracting the end effector away from the carrier to unload the workpiece from the carrier and advancing the end effector back toward the carrier to load the workpiece back into the carrier; and rotating the end effector relative to the carrier to invert the workpiece in electronic synchronization with the retracting and advancing of the end effector for loading the workpiece back into the carrier when inverted.Type: ApplicationFiled: March 18, 2024Publication date: September 19, 2024Inventors: Kenneth Wayne NICHOLSON, Philip David Munroe, James Mark McLean, Robert James MacGregor, David Andrew Tait, Gustavo Barea, Roger Craig Hogan
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Publication number: 20240140729Abstract: There is provided a device, system, and method for flexible feeding capable of being integrated into an assembly system. The device includes a disperser, a part retainer, a vibrator, an excess part removal device, a pick-and-placer, carriers, a transporter, a carrier inspection disc, a part remover, a gate, a transfer station, and re-entry tracks. The method includes dispersing parts, agitating parts, removing excess parts, picking captured parts, placing the captured parts into carriers, inspecting the carriers, positioning the carriers at a transfer station, and transferring the parts to a downstream processor. The system includes a flexible feeding device configured to perform flexible feeding operations, a data processor, and a medium having machine-readable instructions executable by the data processor and configured to cause the data processor to generate signals useful in the synchronization of two or more flexible feeding operations.Type: ApplicationFiled: January 3, 2024Publication date: May 2, 2024Inventor: Kenneth Wayne NICHOLSON
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Patent number: 11932497Abstract: A method of inverting workpieces in a mass production process includes: advancing an end effector in electronic synchronization with advancement of a carrier to synchronize arrival of the carrier at a stop position with arrival of the end effector at an unloading position, in which the end effector is in alignment with a workpiece held by the carrier for engaging the workpiece; while the end effector is in engagement with the workpiece, retracting the end effector away from the carrier to unload the workpiece from the carrier and advancing the end effector back toward the carrier to load the workpiece back into the carrier; and rotating the end effector relative to the carrier to invert the workpiece in electronic synchronization with the retracting and advancing of the end effector for loading the workpiece back into the carrier when inverted.Type: GrantFiled: March 17, 2022Date of Patent: March 19, 2024Assignee: ATS CORPORATIONInventors: Kenneth Wayne Nicholson, Philip David Munroe, James Mark McLean, Robert James MacGregor, David Andrew Tait, Gustavo Barea, Roger Craig Hogan
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Patent number: 11905128Abstract: There is provided a device, system, and method for flexible feeding capable of being integrated into an assembly system. The device includes a disperser, a part retainer, a vibrator, an excess part removal device, a pick-and-placer, carriers, a transporter, a carrier inspection disc, a part remover, a gate, a transfer station, and re-entry tracks. The method includes dispersing parts, agitating parts, removing excess parts, picking captured parts, placing the captured parts into carriers, inspecting the carriers, positioning the carriers at a transfer station, and transferring the parts to a downstream processor. The system includes a flexible feeding device configured to perform flexible feeding operations, a data processor, and a medium having machine-readable instructions executable by the data processor and configured to cause the data processor to generate signals useful in the synchronization of two or more flexible feeding operations.Type: GrantFiled: October 17, 2019Date of Patent: February 20, 2024Assignee: ATS CorporationInventor: Kenneth Wayne Nicholson
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Publication number: 20230242351Abstract: A conveyor system and method for controlling the same. The conveyor system includes: at least one moving element; a track including: a straight track section with a first mechanism for moving the moving element; and a curved track section connected to the straight track section including a second mechanism for moving the moving element; and a controller configured to control a speed of the moving element as the moving element moves from the straight track section to the curved track section and vice versa such that a velocity profile of the moving element includes a sinusoidal portion to provide a transition from straight to rotary motion or from rotary to straight motion having a linear position profile. In the method, the controller controls at least one of the first mechanism and the second mechanism to move the moving element according to the velocity profile including the sinusoidal portion.Type: ApplicationFiled: February 3, 2023Publication date: August 3, 2023Inventors: Roger HOGAN, Blake Robert LAMBERT, Anton DOLGOVYKH, Braden Jon GUENTHER, Philip David MUNROE, Albert John KLEINIKKINK, Kenneth Wayne NICHOLSON
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Patent number: 11692552Abstract: Systems and methods of flow testing different workpieces in an automated testing station are described. Each workpiece comprises a flow path from an inlet to an outlet and the automated testing station comprises first and second sealing heads for injecting gas into the inlets of workpieces and collecting gas from the outlets of workpieces. The method includes performing a flow test by moving the flow test heads toward the workpieces while at the same time priming a flow of gas from the first sealing heads to the second sealing heads, prior to engaging the workpiece.Type: GrantFiled: March 28, 2022Date of Patent: July 4, 2023Inventors: Kenneth Wayne Nicholson, Philip David Munroe, Mathieu Jocelyn Giles Pascal Gaudreault, Martin George Smith, David Andrew Tait, Robert David Almas, Colin Spencer Quelch
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Publication number: 20230123063Abstract: There is described systems and methods for programming and configuring part-processing devices and production stations. Methods of programming the control system of a part-processing device for controlling one or more tooling components, sensors and/or motion systems includes the step of loading a software backplane onto the control system, the software backplane being configured to run on an operating system of the control system and to interface with one or more configurable applications. The method also comprises the step of loading one or more configurable applications associated with the one or more tooling components onto the control system, the one or more applications being configured to interface with the software backplane. The method also comprises the step of configuring the one or more configurable applications to control the one or more tooling components, sensors and/or motion systems pf the part-processing device.Type: ApplicationFiled: October 11, 2022Publication date: April 20, 2023Inventors: Kenneth Wayne Nicholson, Robert David Almas, Philip David Munroe, James Mark McLean
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Publication number: 20230083483Abstract: A method of repitching workpieces in an automated mass production system includes: (a) unloading a set of workpieces from a plurality of first retainers arranged at a first pitch, the unloading step including gripping of the workpieces by corresponding grippers of a repitch robot; (b) adjusting the workpieces from the first pitch to a second pitch different from the first pitch, the adjusting step including translating the grippers relative to each other from a first spacing corresponding to the first pitch to a second spacing corresponding to the second pitch; and (c) loading the workpieces into a plurality of corresponding second retainers arranged at the second pitch, the loading step including positioning and releasing the workpieces in the second retainers via the grippers.Type: ApplicationFiled: September 6, 2022Publication date: March 16, 2023Inventors: Kenneth Wayne Nicholson, David Andrew Tait, Robert James MacGregor
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Publication number: 20220331965Abstract: A method of processing O-rings in an automated mass production system includes: (a) advancing an O-ring retainer toward a loading position in alignment with an output end of a feed device; (b) discharging a leading O-ring from the output end in electronic synchronization with advancement of the O-ring retainer to the loading position to initiate loading of the O-ring into the retainer prior to the retainer arriving at the loading position; (c) after loading the O-ring into the retainer, advancing the retainer away from the loading position toward an unloading position; and (d) moving an end effector in electronic synchronization with advancement of the retainer to the unloading position to synchronize arrival of the retainer at the unloading position with arrival of the end effector at a pick-up position in alignment with the O-ring at the unloading position for pick up of the O-ring by the end effector.Type: ApplicationFiled: March 17, 2022Publication date: October 20, 2022Inventors: Kenneth Wayne Nicholson, Philip David Munroe, James Mark McLean, Robert James MacGregor, David Andrew Tait, Gustavo Barea, Roger Craig Hogan
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Publication number: 20220332519Abstract: A method of inverting workpieces in a mass production process includes: advancing an end effector in electronic synchronization with advancement of a carrier to synchronize arrival of the carrier at a stop position with arrival of the end effector at an unloading position, in which the end effector is in alignment with a workpiece held by the carrier for engaging the workpiece; while the end effector is in engagement with the workpiece, retracting the end effector away from the carrier to unload the workpiece from the carrier and advancing the end effector back toward the carrier to load the workpiece back into the carrier; and rotating the end effector relative to the carrier to invert the workpiece in electronic synchronization with the retracting and advancing of the end effector for loading the workpiece back into the carrier when inverted.Type: ApplicationFiled: March 17, 2022Publication date: October 20, 2022Inventors: Kenneth Wayne NICHOLSON, Philip David Munroe, James Mark McLean, Robert James MacGregor, David Andrew Tait, Gustavo Barea, Roger Craig Hogan
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Publication number: 20220316482Abstract: Systems and methods of flow testing different workpieces in an automated testing station are described. Each workpiece comprises a flow path from an inlet to an outlet and the automated testing station comprises first and second sealing heads for injecting gas into the inlets of workpieces and collecting gas from the outlets of workpieces. The method includes performing a flow test by moving the flow test heads toward the workpieces while at the same time priming a flow of gas from the first sealing heads to the second sealing heads, prior to engaging the workpiece.Type: ApplicationFiled: March 28, 2022Publication date: October 6, 2022Inventors: Kenneth Wayne Nicholson, Philip David Munroe, Mathieu Jocelyn Giles Pascal Gaudreault, Martin George Smith, David Andrew Tait, Robert David Almas, Colin Spencer Quelch