ROTARY WHEELHOUSE ROLLER HEMMING ASSEMBLY

Abstract

A rotary wheelhouse roller hemming apparatus in accordance with the present invention includes a support and a rotary mechanism including a plurality of connected anvils driveably rotatable about an axis. The rotary mechanism is mounted on the support. Rotation of the rotary mechanism about the axis moves the anvils between use and standby, non-use positions.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the priority of U.S. Provisional Application No. 61/753,629 filed Jan. 17, 2013.

TECHNICAL FIELD

This invention relates to vehicle body panel production, and more particularly to robotic roller hemming used in vehicle production.

BACKGROUND OF THE INVENTION

Conventional wheelhouse roller hemming systems remove and replace anvils as required per model selection, e.g. for each different model of vehicle. As assembly systems are moving towards flexibility, the need to hem multiple products (models) in an assembly line is becoming required.

SUMMARY OF THE INVENTION

The present invention provides a rotary wheelhouse roller hemming assembly and system that efficiently switches between hemming anvils for multi-model selection in a single cell. The present hemming assembly and system keeps the hemming anvils attached to a rotary apparatus and eliminates transfer of anvils from storage stands to the hemming assembly in order to reduce cost and increase safety and jobs-per-hour (JPH). Thus, the present hemming assembly and system may have one or more of the following advantages over a conventional removable anvil system: (i) minimal cycle time for style change-out in comparison to conventional anvil change-out, resulting in higher JPH; (ii) 360° rotation in either direction (i.e., clockwise, counterclockwise); (iii) selection among a plurality of model styles; (iv) independent 3-way anvil adjustment; (v) less robot programming because the movement of anvils to stands is not required; (vi) less maintenance and increased safety because standing on ladders to program robot paths from the apparatus to offline storage stands is not required; (vii) approximately 40% less use of floor space; and (viii) reduced robot size requirements.

More particularly, a rotary wheelhouse roller hemming apparatus in accordance with the present invention includes a support and a rotary mechanism including a plurality of connected anvils driveably rotatable about an axis. The rotary mechanism is mounted on the support. Rotation of the rotary mechanism about the axis moves the anvils between use and standby, non-use positions.

In one embodiment, each of the anvils is configured for hemming a different model of workpiece. The rotary mechanism includes six of the anvils, and the anvils are configured for hemming vehicle wheelhouse panels. The rotary mechanism is rotatable 360 degrees in both clockwise and counterclockwise directions. The rotary mechanism is driven by a robotic arm, a servo motor, or a VFD motor. The support is a slideable frame.

In a specific embodiment, a rotary wheelhouse roller hemming apparatus in accordance with the present invention includes a support and a rotary anvil assembly mounted on the support. The rotary anvil assembly includes a backing plate mounted on the support. A mounting plate is rotateably connected to the backing plate. A plurality of different anvils are radially disposed on and around the perimeter of the mounting plate. Rotation of the mounting plate moves the anvils between use and standby, non-use positions.

The mounting plate may be rotatable 360 degrees in both clockwise and counterclockwise directions. A plurality of indexing features may be spaced at regular intervals on a rear face of the backing plate. A locking device may be mounted on the support. The locking device is cooperable with each indexing feature to lock the mounting plate. A pivot bearing assembly may couple the backing plate to the mounting plate. A connector may be mounted on a rear face of the mounting plate. The connector is engageable by a robot end effector, and may extend through a generally central opening in the backing plate. The rotary anvil assembly may be driven by a robotic arm, a servo motor, or a VFD motor. The support may be a slideable frame slideable on a base in both a fore and aft direction and a left and right direction. Sliding movement of the support may be driven by a robotic arm.

A rotary wheelhouse roller hemming system in accordance with the present invention includes a multi-axis robotic arm. A roller hemming head is mounted on an end of the robotic arm for roller hemming. A slide mechanism for multi-directional movement is mounted on a base. A support is mounted on the slide mechanism. A rotary anvil assembly is pivotally mounted on the support. The rotary anvil assembly includes a backing plate mounted on the support, a mounting plate pivotally connected to the backing plate, and a plurality of different anvils radially disposed on and around the perimeter of the mounting plate. Rotation of the mounting plate moves the anvils between use and standby, non-use positions.

Optionally, a connector may be mounted on a rear face of the mounting plate. The connector is engageable by the roller hemming head. The robotic arm is operable to manipulate the roller hemming head into engagement with the connector, and subsequent movement of the robotic arm moves the support on the slide mechanism, thereby adjusting the position of the anvil relative to a workpiece to be hemmed, and subsequent rotation of the roller hemming head rotates the mounting plate to interchange the anvils.

A method of interchanging roller hemming anvils in accordance with the present invention includes the steps of: mounting a rotary mechanism on a support, the rotary mechanism including a plurality of connected anvils driveably rotatable about an axis; and rotating the rotary mechanism about the axis to move the anvils between use and standby, non-use positions. The method may further include the step of driving the rotary mechanism via one of a robotic arm, a servo motor, and a VFD motor.

These and other features and advantages of the invention will be more fully understood from the following detailed description of the invention taken together with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a rotary wheelhouse roller hemming assembly and system in accordance with the present invention;

FIG. 2 is another perspective view of the roller hemming assembly;

FIG. 3 is yet another perspective view of the roller hemming assembly;

FIG. 4 is an enlarged view of a portion of a sliding mechanism of a slideable support frame of the roller hemming assembly;

FIG. 5 is an enlarged view of a rear portion of the roller hemming assembly;

FIG. 6 is an enlarged view of a front portion of the roller hemming assembly;

FIG. 7A is a perspective view of a roller hemming head end effector of a multi-axis robotic arm of the roller hemming system in a first, unlocked disposition;

FIG. 7B is a perspective view of the roller hemming head end effector in a second, locked disposition;

FIG. 8A is a perspective view of the roller hemming head end effector approaching a complimentary drive member of the roller hemming assembly;

FIG. 8B is a perspective view of the roller hemming head end effector engaging the drive member;

FIG. 8C is a perspective view of the roller hemming head end effector moving to a locking position relative to the drive member;

FIG. 8D is another perspective of the roller hemming head end effector moving to a locking position relative to the drive member;

FIG. 8E is a sectional view of the roller hemming head end effector and drive member of FIG. 8D illustrating a locking pin of the end effector in the unlocked disposition;

FIG. 8F is a perspective view of the roller hemming head end effector locking with the drive member;

FIG. 8G is a sectional view of the roller hemming head end effector and drive member illustrating the locking pin of the end effector in the locked disposition;

FIG. 9 is an enlarged view of a rear portion of the roller hemming assembly illustrating an anvil position locking device;

FIG. 10 is a perspective view of the roller hemming system illustrating the robotic arm in a position for driving the rotary mechanism and a position for performing roller hemming;

FIG. 11 is a perspective view of an alternative embodiment of a rotary wheelhouse roller hemming assembly and system in accordance with the present invention in which the rotary mechanism is driven by a servo motor; and

FIG. 12 is a perspective view of yet another alternative embodiment of a rotary wheelhouse roller hemming assembly and system in accordance with the present invention in which the rotary mechanism is driven by a VFD motor.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings in detail, numeral 110 generally indicates rotary wheelhouse roller hemming system in accordance with the present invention. The roller hemming system 110 includes a rotary mechanism having a plurality of connected anvils driveably rotatable about an axis. Rotation of the rotary mechanism about the axis interchanges the anvils between use and standby, non-use positions. The roller hemming system 110 thereby provides greater flexibility, faster production rates, reduced floor space requirements, easier model change-out, and greater safety.

Turning to FIGS. 1-4, in one embodiment the roller hemming system 110 includes a support 112. The support 112 may be a fixed pedestal, or as shown in this embodiment, may be a generally vertically disposed frame 114 mounted on a sliding mechanism 116 that allows for multi-directional movement of the support in both a fore-aft direction (forward and backward) and a cross-car direction (left and right). The slide mechanism 116 includes a first track 118 mounted on a base 120, first slides 122 slideably engaged with the first track 118, a second track 124 mounted on the first slides 122, and second slides 126 slideably engaged with the second track 124. The first track 118 includes a set of parallel rails such as linear rails or similar and the second track 124 similarly includes a set of parallel rails. The second track 124 is generally perpendicular to the first track 118. In this orientation, the first track 118 allows for forward and backward movement while the second track 124 allows for left and right movement. Rail brakes 128 are connected to first and second slides 122, 126. The rail brakes 128 may be pneumatically operated and when activated may mechanically lock on the rails to restrict or prevent movement of the slides 122, 126 along the rails.

A rotary assembly 130 is mounted on the support 112 generally at an upper end of the frame 114. As shown in FIGS. 5 and 6, the rotary assembly 130 includes a backing plate 132 fixedly mounted on the frame 114 and a rotary mounting plate 134 rotateably connected to the backing plate 132 via a slew bearing, roller bearing, gear box, or similar rotary mechanism. A plurality of anvil assemblies 136 are radially disposed around the perimeter of and connected to the rotary mounting plate 134. In the embodiment shown in the drawings, the apparatus includes six anvil assemblies. However, it should be understood that the apparatus may include less than or more than six anvil assemblies depending upon the application, for example an arrangement of four anvil assemblies. Each anvil assembly 136 includes an anvil mounting plate 138 fixedly connected to the rotary mounting plate 134. Each anvil assembly 136 further includes an anvil 140 having its own unique configuration (e.g., dimension, shape of hemming surface, etc.) that is different than the other anvils, for hemming a wheelhouse of a specific vehicle model. The anvil 140 is adjustably mounted on the anvil mounted plate 138 via a plurality of jack screw adjusters 142 and a plurality of ball screw pivot adjusters 144 that precisely orient the anvil on the anvil mounting plate 138. The jack screw adjusters 142 move the anvil in a up/down or left/right direction relative to the anvil mounting plate 138, while the ball screw pivot adjusters 144 move the anvil toward/away from (in/out) the anvil mounting plate 138. The jack screw adjusters 142 and ball screw pivot adjusters 144 may be GIB-type fasteners or similar.

A robotically actuated drive member 146 extends outwardly from a back side of the mounting plate 134 through a generally circular opening 148 in the backing plate 132, as shown, for example, in FIGS. 5 and 9. A keyed receiver 150 is connected to an outer end of the drive member 146. The receiver 150 includes a shoe 152 having a slot 154 formed by opposing flanged surfaces 156 and stops 158 disposed at one end of the slot. The receiver 150 also includes a pin hole 160.

A multi-axis articulated robotic arm 162 including a roller hemming head end effector 164 is disposed proximate the support 112. The multi-axis robotic arm 162 is fixedly mounted on a pedestal 166 or other similar base. As shown in FIGS. 7A and 7B, the roller hemming head 164 includes a plate 168 on which a sliding block 170 is slideably mounted on a linear rail 171 for back-and-forth (inward and outward) movement. A plurality of hemming rollers 172, such as, for example, 30 degree and 60 degree pre-hem rollers and a 90 degree final hem roller, are rotateably mounted on sides of the sliding block 170. A locking pin 173 is mounted on the front (forward face) of the sliding block 170. A pneumatic cylinder 174 or other similar linear actuation device is fixedly mounted proximate an inner end of the roller head 164. The pneumatic cylinder 174 includes a piston 175 (see FIGS. 8E and 8G) that is connected to the sliding block 170 via a rod 176 to actuate linear movement of the sliding block. A locking member 177 is fixedly mounted on a distal end of the roller head 164. The locking member 177 is mateable with the receiver 150 on the rotary assembly 130. The locking member 177 includes a keyed protrusion 178 that is insertable into the slot 154 of the receiver 150. An opening 179 through the locking member 177 receives the locking pin 173, and actuation of the pneumatic cylinder 174 causes the sliding block 170 to move towards the locking member 177 and the locking pin 173 to extend outwardly through the opening 179. Extension of the locking pin 173 when the roller head 164 is mated with the receiver 150 secures the roller head to the rotary assembly 130, as described in more detail below.

When the roller head 164 is locked in connection with the rotary assembly 130, rotation of the roller head 164 (turning of the roller head about an axis that extends through the pneumatic cylinder 174 and locking pin 173) driveably rotates the rotary mounting plate 134. The rotary mounting plate 134 is capable of 360 degree rotation in either a clockwise direction or a counterclockwise direction to interchange the anvil assemblies 136 between a use position (in this case, a position at which the anvil assembly is at the bottom of the rotary mounting plate, facing downward) and standby, non-use positions (the other positions around the rotary mounting plate).

As shown in FIGS. 5 and 9, a plurality of indexing features 180 are spacedly disposed on a rear face of rotary mounting plate 134. An anvil position locking device 181 is mounted on the frame 114 and includes a catch 182 having a cam surface 183 cooperable with the indexing features 180. The catch 182 is operatively connected to a lever arm 184. A resilient member such as a spring or similar may urge the lever arm 184 and connected catch 182 into engagement with one of the indexing features 180. Rotation of the rotary mounting plate 134 and corresponding movement of the indexing feature 180 causes the indexing feature to travel along the cam surface 183 and push the catch 182 and lever arm 184 away from the indexing feature to release the rotary mounting plate from the locking device 181. When the next indexing feature 180 along the periphery of the rear face of the rotary mounting plate 134 comes into contact with the catch 182, the rotary mounting plate is again restricted in its movement. The position of the indexing features 180 relative to the catch 182 corresponds to radial positions of the rotary mounting plate 134 at which each of the anvil assemblies 136 is in a use disposition for roller hemming of a vehicle wheelhouse or other workpiece.

In use, the support 112 and robotic arm 162 may be, for example, mounted on the floor of a roller hemming work cell. A vehicle panel (not shown) including a wheelhouse is transported into the hemming work cell for hemming of the wheelhouse. As shown in detail in FIGS. 8A-G, the robotic arm 162 moves the roller hemming head 164 into alignment with the receiver 150 on the drive member 146 such that the protrusions 178 of the locking member 177 are aligned with the keyed openings in the slot 154 (FIG. 8A). The robotic arm 162 then moves the roller hemming head 164 toward the receiver 150 until the locking member 177 is disposed in the slot 154 (FIG. 8B). The robotic arm 162 proceeds to move the roller hemming head 164 so that the locking member 177 slides inwardly along the slot 154 until the locking member 177 contacts the stops 158, and the locking pin 173 is aligned with the pin hole 160 (FIGS. 8C, 8D, 8E). The pneumatic cylinder 174 is actuated to extend the piston 175 outwardly, moving the sliding block 170 toward the receiver 150 which in turn moves the locking pin 173 into the pin hole 160 to secure the connection of the robotic arm 162 to the drive member 146 (FIGS. 8F, 8G).

Rotation of the robotic arm 162, either in a clockwise or counterclockwise direction, along an axis passing through/parallel to the longitudinal axis of the roller hemming head 164, rotates the rotary mounting plate 134 to switch and select which hemming anvil is in a use position at the bottom of the rotary mounting plate. As each anvil assembly 136 is moved into the use position, the catch 182 of the locking device 181 engages an adjacent indexing feature 180 on the rotary mounting plate 134. Once the desired anvil assembly 136 is selected, the robotic arm 162 ceases to rotate the roller hemming head 164 and connected drive member 146.

While the robotic arm 162 is connected to the drive member 146, the robotic arm may adjust the positioning of the support frame 114 to correct for misalignment of the anvil 140 relative to the wheelhouse or other workpiece to be hemmed. By moving in a left or right direction, the robotic arm slides the frame 114 along the second track 124, thereby moving the support frame and anvil 140 along the side of the workpiece. Similarly, by moving in a forward or backward direction, the robotic arm 162 slides the frame 114 along the first track 118, thereby moving the support frame 114 and anvil 140 closer to or farther away from the workpiece. Once the support frame 114 is in the desired position, the rail brakes 128 may be activated to lock the support frame in place.

The position of the anvil 140 relative to the workpiece may also be finely adjusted by the jack screw adjusters 142 and the ball screw pivot adjusters 144. Manual rotation of the jack screw adjusters 142 moves the anvil 140 up/down and left/right relative to the workpiece to precisely align the anvil with the portion of the workpiece to be hemmed (e.g., the wheelhouse of a vehicle panel). Manual rotation of the ball screw pivot adjusters 144 moves the anvil 140 toward and away from the workpiece to precisely position the anvil relative to the workpiece in the transverse direction. The anvil 140 generally should be positioned so that the portion of the workpiece to be hemmed is adjacent the hemming surface of the anvil.

With reference to FIG. 10, to perform hemming of the wheelhouse of the vehicle panel, the robotic arm 162 must release from the drive member 146. The pneumatic cylinder 174 is returned to its initial position (FIG. 8E) to retract the locking pin 173, which allows the robotic arm 162 to move the locking member 177 out of the receiver 150, thereby freeing the robotic arm. The robotic arm then can position one of the hemming rollers 172 of the roller head 164 against an edge of the workpiece that is disposed on the hemming surface of the anvil 140, and the robotic arm 162 moves the hemming roller 172 along the anvil's hemming surface to perform the hemming operation (e.g., a pre-hem or final hem). The robotic arm 162 also may rotate the roller head 164 about the longitudinal axis of the head to change between the hemming rollers 172.

While the roller hemming system 110 described above includes a robot driven rotary anvil changer, the rotary assembly alternatively may be actuated by an active drive. For example, the active drive may be a servo motor or a VFD motor, and the drive may be in line with a gearbox on the rotary assembly or may transfer power to the gearbox via a rotary belt system.

As shown in FIG. 11, in an alternative embodiment, the roller hemming system 210 is driven by a servo motor 285. The servo motor 285 is coupled to a pivot bearing assembly 286 by a belt 287. The pivot bearing assembly 286 is connected to the rotary mounting plate 234 of the rotary mechanism. The roller hemming system 210 otherwise may include all of the same structure and function as in the first embodiment 110.

As shown in FIG. 12, in yet another alternative embodiment, the roller hemming system 310 is driven by a VFD (variable-frequency drive) motor 388. The VFD motor 388 is in line with the pivot bearing assembly 389 and reduction gearbox 390 on the rotary mounting plate 334. The roller hemming system 310 otherwise may include all of the same structure and function as in the first embodiment 110.

While the roller hemming system has been described in connection with the hemming of a vehicle wheelhouse, the system may be used with anvils for hemming other portions of vehicle panels or other hemming applications.

Although the invention has been described by reference to specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims.

Claims

1. A rotary wheelhouse roller hemming apparatus comprising:

a support; and

a rotary mechanism including a plurality of connected anvils driveably rotatable about an axis;

said rotary mechanism being mounted on said support;

wherein rotation of said rotary mechanism about said axis moves said anvils between use and standby, non-use positions.

2. The rotary wheelhouse roller hemming apparatus of claim 1, wherein each of the anvils is configured for hemming a different model of workpiece.

3. The rotary wheelhouse roller hemming apparatus of claim 1, wherein said rotary mechanism includes six anvils.

4. The rotary wheelhouse roller hemming apparatus of claim 1, wherein said rotary mechanism is rotatable 360 degrees in both clockwise and counterclockwise directions.

5. The rotary wheelhouse roller hemming apparatus of claim 1, wherein said rotary mechanism is driven by one of a robotic arm, a servo motor, and a VFD motor.

6. The rotary wheelhouse roller hemming apparatus of claim 1, wherein said support is a slideable frame.

7. A rotary wheelhouse roller hemming apparatus comprising:

a support; and

a rotary anvil assembly mounted on said support;

said rotary anvil assembly including: a backing plate mounted on said support; a mounting plate rotateably connected to said backing plate; and a plurality of different anvils radially disposed on and around the perimeter of said mounting plate;

wherein rotation of said mounting plate moves said anvils between use and standby, non-use positions.

8. The rotary wheelhouse roller hemming apparatus of claim 7, wherein said mounting plate is rotatable 360 degrees in both clockwise and counterclockwise directions.

9. The rotary wheelhouse roller hemming apparatus of claim 7, including a plurality of indexing features spaced at regular intervals on a rear face of said backing plate.

10. The rotary wheelhouse roller hemming apparatus of claim 9, including a locking device mounted on said support, said locking device being cooperable with each said indexing feature to lock said mounting plate.

11. The rotary wheelhouse roller hemming apparatus of claim 7, including a pivot bearing assembly that couples said backing plate to said mounting plate.

12. The rotary wheelhouse roller hemming apparatus of claim 7, including a connector mounted on a rear face of said mounting plate, said connector being engageable by a robot end effector.

13. The rotary wheelhouse roller hemming apparatus of claim 12, including a generally central opening in said backing plate, said connector extending through said opening.

14. The rotary wheelhouse roller hemming apparatus of claim 7, wherein said rotary anvil assembly is driven by one of a robotic arm, a servo motor, and a VFD motor.

15. The rotary wheelhouse roller hemming apparatus of claim 7, wherein said support is a slideable frame slideable on a base in both a fore and aft direction and a left and right direction.

16. The rotary wheelhouse roller hemming apparatus of claim 15, wherein sliding movement of said support is driven by a robotic arm.

17. A rotary wheelhouse roller hemming system comprising:

a multi-axis robotic arm;

a roller hemming head mounted on an end of said robotic arm for roller hemming;

a slide mechanism for multi-directional movement mounted on a base;

a support mounted on said slide mechanism;

a rotary anvil assembly pivotally mounted on said support, said rotary anvil assembly including: a backing plate mounted on said support; a mounting plate pivotally connected to said backing plate; and a plurality of different anvils radially disposed on and around the perimeter of said mounting plate;

wherein rotation of said mounting plate moves said anvils between use and standby, non-use positions.

18. The rotary wheelhouse roller hemming system of claim 17, including a connector mounted on a rear face of said mounting plate, said connector being engageable by said roller hemming head;

wherein said robotic arm is operable to manipulate said roller hemming head into engagement with said connector, and subsequent movement of said robotic arm moves said support on said slide mechanism, thereby adjusting the position of said anvil relative to a workpiece to be hemmed, and subsequent rotation of said roller hemming head rotates said mounting plate to interchange said anvils.

19. A method of interchanging roller hemming anvils, the method comprising the steps of:

mounting a rotary mechanism on a support, said rotary mechanism including a plurality of connected anvils driveably rotatable about an axis; and

rotating said rotary mechanism about said axis to move said anvils between use and standby, non-use positions.

20. The method of claim 19, including the step of:

driving said rotary mechanism via one of a robotic arm, a servo motor, and a VFD motor.