Robotic turntable

[0002] This application is a divisional of prior application Ser. No. 09/813,766 for a ROBOTIC TURNTABLE, filed on Mar. 21, 2001 now U.S. Pat. No. 6,435,397 which claimed the benefit of prior provisional application Ser. No. 60/197,614 filed Apr. 18, 2000.

[0003] The present invention relates to a plurality of robots positioned on a turntable at spaced locations along the periphery, where the turntable is movable in rotation to predetermined angular positions independently of movement of the individual robots disposed thereon.

[0004] A modular robotic finishing work center is disclosed in U.S. Pat. No. 4,644,897. The patent discloses an elevated platform with a turntable mounted thereon which is rotatable about a vertical axis, and a robot manipulator fixedly mounted relative to the vertical axis, wherein the turntable ends are rotatable through a circular path where at least part of the path includes a partially protected booth for collecting paint residue and overspray. The robot manipulator has a movable arm and spray applicator capable of movement along a limited range so as to provide a predetermined envelope of possible work areas for spray finishing, where a portion of the turntable end path and at least a portion of the spray booth are included within this envelope.

[0005] A tool turntable for a manufacturing system is disclosed in U.S. Pat. No. 5,186,304. The production line manufacturing system includes a programmable multi-position rotatable unit that can be used in each of the work stations to accommodate both changes in workpieces to be processed and tools. The rotatable unit includes a four-position horizontally arranged fixture table including four vertically arranged fixtures movably mounted thereon. A precision locator key on each of the fixtures positions each individual fixture on the table and also serves as a positive fixture stopped in the work position.

[0006] It would be desirable in the present invention to provide a turntable or a carousel with a plurality of robots positioned thereon in peripherally spaced locations with respect to one another for movement about a vertical axis of the turntable while allowing independent movement of each of the individual robots positioned thereon. The apparatus for manufacturing parts according to the present invention can include a turntable having an outer periphery and a centrally located axis of rotation, a plurality of robots positioned at peripherally spaced locations about the turntable with respect to one another for independent movement with respect to one another and with respect to movement of the turntable, and a control system for controlling and synchronizing independent individual movements of the robots with rotation of the turntable to move each individual robot from one work station at a first angular position to another work station at a second angular position.

[0007] Other objects, advantages and applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.

[0008] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:

[0009] FIG. 1 is a simplified plan view of a robotic turntable or carousel according to the present invention for manufacturing parts; and

[0010] FIG. 2 is a side elevational view of a robotic turntable according to the present invention including a plurality of robots individually operating with respect to different work stations on opposite sides of the turntable.

[0011] An apparatus 10 according to the present invention provides for the manufacturing of parts 12 by a plurality of robots 14 positioned on a turntable 16 for rotation about an axis 18. The robots are positioned at different locations spaced along the outer periphery of the turntable 16. In the illustrated embodiment, there are an equal number of robots 14 to the number of work stations 20 positioned around the periphery of the turntable 16, although an equal number of robots to work stations is not required to practice the present invention. By way of example, and not limitation, the present invention will be described in detail with respect to the manufacture of particular parts 12, such as a side panel sub assembly of a motor vehicle.

[0012] Referring now to FIG. 1, the turntable 16 is illustrated having eight robots 14a, 14b, 14c, 14d, 14e, 14f, 14g, 14hdisposed at evenly spaced angular positions around the outer peripheral edge of the turntable 16. The robots 14a-14hare independently movable with respect to one another, and are movable independent of movement of the turntable 16. When the turntable 16 is disposed at a first angular position, such as that illustrated in FIG. 1, each robot 14 is capable of performing various independent work cycles at the individual work station 20 corresponding to its current location. By way of example and not limitation, in the position illustrated in FIG. 1, the robot 14ais positioned at work station 20afor unloading parts that have been processed. After unloading a part, the turntable 16 can be rotated about the axis 18 to now position the robot 14aat the position previously occupied by robot 14b. In this position, the robot has access to a tool change work station 20bin order to provide the opportunity to change the tooling as required for the particular part to be processed next.

[0013] After completion of the tool change, if any, at work station 20b, the turntable 16 can be rotated again about the axis 18 to move the robot 14afrom the position previously shown for robot 14bto the position previously shown for robot 14c. When in this position, the robot can pick up a part to be processed at the part loading fixture 22 at work station 20c. Preferably, the fixture 22 located at the work station 20cis an indexing part load fixture 22ccapable of positioning a plurality of fixtures corresponding to the desired body style and model to be processed through the work station 20c. In its most preferred configuration, the indexing fixture 22cincludes four different fixtures positioned on four major surfaces of a rectangular fixture rotatable about a horizontal axis to position one of the four major surfaces in an upright ready position for receiving parts to be loaded onto or picked up by the robot at work station 20c.

[0014] After the robot has retrieved the part to be processed from the work station 20c, the turntable 16 is rotated about the axis 18 to bring the robot 14ainto the position previously illustrated for robot 14dcorresponding to work station 20d. At work station 20d, the robot 14apositions the part 12 into the fixture 22dallowing additional work to be performed on the part. The fixture 22dis preferably an indexing part fixture similar to fixture 22c. The fixture 22dpreferably has four major surfaces with different fixtures for various models and body styles to be processed. The fixture is rotatable about a horizontal axis to bring a selected one of the four major surfaces into an upright ready position for receiving the next part to be processed. The additional work can include the attachment and assembly of various sub components to the part, or the clamping and welding of various components at different positions on the part, or any other automated processing required with respect to the particular part being processed through the apparatus 10 according to the present invention. The processing can include assembly and/or welding by additional robots 24a-24ddisposed at work station 20d. One or more robots 24 can be positioned at the work station 20das required for the particular part processing to take place at the particular work station. After the processing of the part is completed at work station 20dand the robot 14aretrieves the part from the fixture 22d, the turntable 16 is rotated about the axis 18 to move the robot 14ato the position previously illustrated for robot 14e. At this position, additional processing can take place as required for the particular part. By way of example and not limitation, the illustration shows a respot work station 20efor welding areas of the part inaccessible while resting in the fixture 22dof work station 20d. A respot welder 26 can be positioned at each respot work station, such as welder 26eat work station 20e.

[0015] After respotting has been completed at the work station 20e, the turntable 16 can be rotated about axis 18 to position the robot 14ain the position previously shown for robot 14f. The part can be loaded by the robot into the fixture 22fat the work station 20f. The fixture 22fpreferably can be an indexing part fixture similar to 22dand 22cpreviously described. In the most preferred configuration, the indexing part fixture 22fis provided as a rectangular fixture having four major surfaces with different fixtures for the various models and body styles to be processed through the apparatus 10 according to the present invention. The rectangular fixture is rotatable about a horizontal axis to bring a selected one of the four major fixture surfaces into an upright ready position for receiving the part to be processed. The processing at the work station 20fcan include assembly of additional sub components to the primary part being assembled, or additional clamping and welding of various portions of the part to one another. Additional robots 26a-26dcan be provided at the work station 20fto perform the assembly or welding operations as required.

[0016] When processing of the part has been completed at the work station 20f, the turntable 16 can be rotated about the axis 18 to position the robot 14aat the position previously illustrated for robot 14g. Additional processing of the part can take place at work station 20gwhen the robot is in this position. By way of example and not limitation, a respot welding apparatus 26gcan be provided to weld portions of the part 12 being assembled that could not be accessed while the part was positioned in the fixture at work station 20f.

[0017] After respotting has been completed, the turntable 16 can be rotated about the axis 18 to position the robot 14aat the position previously illustrated for robot 14h. At this position, the part can be subjected to additional processing, by way of example and not limitation, such as additional respot welding by a respot welding apparatus 26hat work station 20h. When the additional processing is completed at work station 20h, the turntable 16 can be rotated about the axis 18 to again bring the robot 14ato the position illustrated as 14ain FIG. 1 where the processed part can be unloaded at the work station 20a.

[0018] While the invention has been described in detail with respect to a single robot 14abeing rotated through the various work stations around the periphery of the turntable 16, it should be apparent to those skilled in the art that the additional robots 14b, 14c, 14d, 14e, 14f, 14g, 14hpositioned on the turntable 16 perform the same operations at the various work stations while rotated through the various work station positions 20b, 20c, 20d, 20e, 20f, 20g, 20h, and that work is simultaneously performed at each work station by each of the robots 14a-14hprior to the turntable being moved to transfer the robots 14a-14hand parts carried by the robots 14a-14hto the next work station 20a-20hin the processing system.

[0019] Referring now to FIG. 2, a cross-sectional elevational view is shown of the robots 14d, 14fon the turntable 16 according to the present invention through work station 20dand work station 20f. As previously described, the robots 14dand 14fcan transport workpieces 12 to the work station 20dand 20frespectively and can load the parts into a corresponding fixture 22d, 22ffor the particular part to be processed. Each of the indexing fixtures 22d, 22fat the work stations 20dand 20fcan be in the form of a rectangular fixture having four major surfaces with different fixture configurations for the various body styles and models to be processed through the work stations. Each of the fixtures 22 is rotatable about an axis 30 to position the desired fixture in the upright ready position for receiving the part to be delivered by the corresponding robot presently positioned at that work station. Welders 32 can be positioned above each of the robots 14, as can best be seen in FIG. 2 where welder 32dis positioned above robot 14dand welder 32fis positioned above robot 14f. The welders 32 positioned above the robots 14 allow additional welding to be performed during a movement cycle of the turntable 16, or while one work station is waiting for completion of work being performed at another work station. In this way, additional work can be performed by the robot 14 and welder 32 between cycles performed at various work stations. The part can be manipulated and moved as required to perform multiple welds with the welders 32, or the respot welders 26e, 26g, 26hat the work stations 20e, 20gand 20h.

[0020] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.