The tooling 230 can be in the form of, for example, one or more workpiece presentation tools for presenting the workpieces at predetermined locations for delivery and/or further processing and/or one or more workpiece processing tools for performing value-added operations on the workpieces. The workpiece presentation tools can be part of, for example, one or more tracks, carriers, conveyors, screws, indexer, actuators, or other devices for, for example, separating workpieces from other workpieces and delivery of the workpieces to a processing tool for subsequent processing. In some examples, the presentation tools can be part of a carrier and configured to, for example, receive one or more workpieces, accelerate the workpieces toward a position (e.g. along a transport track) for a processing station, and present the workpieces at the processing position for processing by one or more processing tools of the station.

Processing tools can be configured to conduct one or more value-added operations on or with the workpieces. For example, the processing tools can be configured to manipulate a workpiece, assemble two or more workpieces together, reorient and/or reposition a workpiece for further processing, etc. In some examples, processing tools can include, e.g. end effectors such as grippers for part manipulation, assembly, reorientation, transfer, repitching, etc. In some examples, the processing tools can comprise grippers of a pick-and-place robot and can be configured to, for example, unload a plurality of workpieces from a first set of retainers holding the workpieces (e.g. of a supply carrier); after unloading, repitch the workpieces to change a spacing therebetween; and after repitching, load the workpieces into a second set of retainers at a different pitch for subsequent processing.

Machine-readable instructions stored in storage component 222 (or in storage 122, 140) can cause the control system 220 (and/or 120) to execute various methods disclosed herein including generation of one or more signals (e.g., output data) useful in operation of the production devices 110. Such machine-readable instructions can be incorporated into one or more computer program products which can be stored on suitable medium or media. In some embodiments, the machine-readable instructions can be executable by processor 224 and/or 124 for generation of signals useful in electronic synchronization of two or more operations carried out by the tooling 230 (e.g. by presentation and processing tools) of the production devices 110. The machine-readable instructions can be executable by the processor(s) for determination and/or selection of control parameters for operation of the tooling 230 and generate signals representative of the control parameters. For example, the machine-readable instructions can be configured to cause processor 224 and/or 124 to generate signals useful in the electronic synchronization of, for example, the delivery of workpieces by a presentation tool and receipt of the workpieces by a processing tool; the processing steps performed by one or more processing tools; and/or delivery of workpieces by the processing tool and receipt of the workpieces by the presentation tool.

The synchronization of two or more operations performed by the tooling 230 of one or more production devices 110 can utilize electronic camming (e.g. instead of mechanical cams, gears, or linkages). Electronic camming can coordinate the actuation of multiple mechanisms through electronic controls and software. The mechanisms need not physically interact and synchronization of their motions is electronically controlled with accuracy and flexibility through software interaction. Electronic camming can link movement of devices through electronic means (i.e. software), conceptually in the same manner that gears, linkages, and timing chains link movements of mechanical devices together, with enhanced accuracy, control, and design flexibility.

In various embodiments, the use of such electronic synchronization can facilitate system flexibility and improve system performance relative to some more-conventional systems utilizing mechanical synchronization means. In some examples, storage component 222 (and/or 122, 140) can hold data representative of one or more cam profiles to be used in the operation of the tooling 230 of one or more production devices 110. For example, such cam profile(s) can be in tabular form and can include corresponding positions representative of synchronized trajectories to be followed by the tooling 230 during operation. In some examples, one tooling component 230 can be operated as a master device and another tooling component 230 can be operated as a slave device executing movements based on the execution of movements by the master device in order to substantially maintain synchronization between the slave device and the master device. In some examples, the production devices 110 can include one or more master devices and one or more respective slave devices. For example, multiple slave devices can be electronically cammed with a master device.

The machine-readable instructions can be configured to cause processor 224 and/or 124 to generate signals useful in electronic synchronization (e.g. camming) of the delivery of a workpiece by a presentation tool and of receipt of the workpiece by a processing tool (or another presentation tool). In some embodiments, the machine-readable instructions can be configured to cause the processor(s) to generate signals useful in electronic synchronization of loading, separation, acceleration, and delivery of a workpiece by a presentation tool and of receipt of the workpiece by a processing tool. In some embodiments, the machine-readable instructions can be configured to cause the processor(s) to generate signals useful in controlling movement of a workpiece along a delivery trajectory and controlling movement of a processing tool along a processing tool trajectory for electronic synchronization of the workpiece and processing tool.

In some examples, the machine-readable instructions can be configured to cause processor 224 and/or 124 to generate signals useful in controlling at least some aspect of the processing of a workpiece. For example, such processing can include one or more value-added operations that can be carried out by the processing tool. Such value-added operation can include, for example, repitching of workpieces and transfer of the workpieces between carriers. The machine-readable instructions may, for example, be configured to cause processor 224 (and/or 124) to generate signals useful in electronic synchronization of the processing of a workpiece and one or more operations associated with presentation and/or processing tools. In some embodiments, the machine-readable instructions can be configured to cause the processor(s) to generate signals useful in controlling translation of a processing tool, translation of subcomponents (e.g. grippers) of the processing tool relative to each other, and/or translation and/or movement of presentation tools and/or subcomponents thereof. In some examples, one or more operations conducted by the presentation or processing tools can be under binary control rather than direct electronic synchronization. In some examples, the triggering of an operation via a binary control signal can be dependent on the position of a master device and can still be based on a cam profile. The production devices 110 can include one or more servo-motors associated with tooling components 230, and the machine-readable instructions can be configured to cause processor 224 and/or 124 to generate signals useful in controlling the servo-motors according to a predetermined cam profile to carry out electronically synchronized operations according to the methods herein.

The production devices 110 can include a numerically synchronized control architecture. For example, transfer and presentation of workpieces (e.g. by presentation tools) according to the methods disclosed herein can include a first computer numerically controlled operation and the receiving of the workpiece (e.g. by a processing tool or another presentation tool) can include a second computer numerically controlled operation. In some examples, the loading, separating, accelerating, and delivering of workpieces can include a first computer numerically controlled operation and the receiving of the workpieces can include a second computer numerically controlled operation. In some examples, the receiving of a workpiece can include a first computer numerically controlled operation and the processing of the workpiece can include a second computer numerically controlled operation. In some examples, the processing of a workpiece can include a first computer numerically controlled operation and the delivery of the workpiece can include a second computer numerically controlled operation. In some examples, the translation of a workpiece can include a first computer numerically controlled operation and the rotation of the workpiece can include a second computer numerically controlled operation. In such examples, the first computer numerically controlled operation and the second computer numerically controlled operation can be electronically synchronized (e.g. electronically cammed).

Referring to FIG. 3, an example implementation 100a of the system 100 is shown schematically. The example system 100a can be configured to carry out steps from processes disclosed herein. System 100a can receive workpieces and/or raw materials as inputs; progressively add value to them via processing tools; and discharge them either as discrete finished products, as unfinished products, or as rejected scrap (i.e., defective products).

As shown in FIG. 3, system 100a can receive the workpieces and/or materials from one or more feeders (e.g. of a feed device including, for example, a supply carrier) for delivering workpieces and/or materials to another presentation tool (e.g. grippers of a part presentation robot). The delivery from the feeders can be done directly or via a respective buffer. Each presentation tool or transfer device of the system 100a can be numerically controlled and configured to deliver the materials and/or workpieces to one or more processing tools (e.g. of a processing device). Each processing tool can add value to a workpiece and/or material via one or more programmable process steps. A given processing tool can operate in parallel to and/or in series with one or more other processing tools and/or presentation tools. Once the workpiece passes through a final processing tool, it can be discharged either as a successfully completed and validated finished product, as an unfinished product, or as rejected scrap. Human interaction with system 100a can be through an operator interface.

The system can include validation stations including validation devices configured to conduct inspections, checks, and/or tests on one or more of the workpieces. In some examples, the validation stations can be located at, for example, one or more feeders, presentation tools, transfer devices, and/or processing tools. At these points, workpieces can be eliminated from the system as scrap if they do not meet one or more predetermined inspection criteria. Validation stations can be configured to conduct inspection, check, and/or test operations on one or more of workpieces that can be electronically synchronized with other devices, such as, for example, a master device of the production devices 110.

The various elements described above can be controlled at least in part by software resources known as base software backplane. The backplane can be configured to permit various elements of the system to carry out various control functions including: management of inputs and outputs; management of local control tasks, including programmable process steps within processing tools and local inspection tasks within validation stations; communications between different elements in the system and communication with a human user via the operator interface.

The system 100a can include a numerically synchronized control architecture. In various embodiments, the feeders, presentation tools, processing tools, and transfer devices can be numerically controlled. Movement of workpieces and materials through the system can occur along programmable axes of motion, which can be either rotary or linear. Movement of tooling associated with the programmable process steps of processing tools can also take place along programmable linear and/or rotary axes of motion.

Referring to FIG. 4, an example arrangement of production devices of the system 100 is shown schematically. In the example illustrated, the system 100 includes a supply track 144 and a plurality of supply carriers 146 advanceable along the supply track 144. In the example illustrated, each supply carrier 146 comprises a tray including a plurality of supply retainers 148 for holding corresponding workpieces 170 for supply to the system 100. In the example illustrated, each of the supply retainers 148 are identical in size and shape, and each of the workpieces 170 are identical in size and shape.

In the illustrated example, the system 100 includes a processing track 150 adjacent the supply track 144 and supporting a plurality of processing carriers 152. Each processing carrier 152 comprises a pallet including a plurality of processing retainers 154 for holding corresponding workpieces 170, and is movable along the track 150 (e.g. through one or more servo-drives) among a plurality of processing stations 160. In the example illustrated, each of the processing retainers 154 are identical in size and shape. Each supply carrier 146 has a quantity of supply retainers 148 and each processing carrier 152 has a quantity of processing retainers 154. The quantity of supply retainers 148 can be at least ten times greater than the quantity of processing retainers 154. In the example illustrated, each supply carrier has 140 supply retainers for holding 140 corresponding workpieces 170, and each processing carrier 152 has seven processing retainers 154 for holding seven corresponding workpieces 170.

Each processing station 160 includes one or more production devices operable in electronic synchronization with each other, the carriers 152, and/or production devices of other processing stations 160 for processing the workpieces 170. In the example illustrated, the processing stations 160 shown in FIG. 4 include a first processing station in the form of a workpiece repitch station 160a for unloading workpieces 170 from corresponding supply retainers 148 arranged at a first pitch 149 in a supply carrier 146 (e.g. by gripping the workpieces with repitch grippers 156 of a repitch robot 162), adjusting the workpieces 170 from the first pitch 149 to a second pitch 159 (e.g. by translating the grippers 156 relative to each other from a first spacing 158a corresponding to the first pitch 149 to a second spacing 158b corresponding to the second pitch 159), and loading the workpieces 170 into corresponding processing retainers 154 arranged at the second pitch 159 in a processing carrier 152 (e.g. by positioning and releasing the workpieces in corresponding retainers 154 via the grippers 156). The second pitch 159 is different from the first pitch 149, and in the example illustrated, the second pitch 159 is greater than the first pitch 149.

A plurality of subsequent processing station 160b are provided along the processing track 150 for performing subsequent value-added operations on the workpieces held by the processing carrier 152; validating, testing, and/or inspecting (and/or performing some other operation on) the workpieces; and/or removing the workpieces from the processing carrier for discharge from the system, either as a successfully completed and validated finished product, as an unfinished product, or as a rejected defective product.

Referring to FIGS. 5 and 5A, a more detailed view of portions of an example repitch station 160a is shown. In the example illustrated, a supply track section 144a of the supply track 144 (FIG. 4) passes through the repitch station 160a. The supply carriers 146 are advanceable along the supply track section 144a to an unloading location therealong. Each supply carrier 146 includes at least one row 147 of supply retainers 148. In the example illustrated, each supply carrier 146 includes a plurality of adjacent rows 147 of supply retainers 148 (twenty rows of seven supply retainers each, in the example illustrated), and each row 147 extends generally parallel with the supply track section 144a. The supply retainers 148 are positioned along each row 147 at regular intervals defined by the first pitch 149 (FIG. 4), and the supply retainers 148 hold corresponding workpieces 170 at the first pitch 149. In the example illustrated, the workpieces 170 are generally cylindrical, and the supply retainers 148 in adjacent rows 147 are offset from each other by about half of the first pitch. This can permit the workpieces in adjacent rows to be positioned in a staggered arrangement and can help increase workpiece density in the supply carrier 146.

In the example illustration, a processing track section 150a of the processing track 150 (FIG. 4) passes through the repitch station 160a, and is arranged in (and extends) parallel with the supply track section 144a. The processing carriers 152 are advanceable along the processing track section 150a to a loading location therealong. Each processing carrier 152 has at least one row 153 of processing retainers 154 for receiving corresponding workpieces 170. In the example illustrated, each processing carrier 152 has a single row 153 of seven processing retainers 154, and the row 153 of processing retainers 154 extends parallel with the processing track section 150a. The processing retainers 154 are positioned along the row 153 at regular intervals defined by the second pitch 159 (FIG. 4).

Referring to FIG. 5A, in the example illustrated, the repitch robot 162 has an end-of-arm tooling (EOAT) platform 164 to which the repitch grippers 156 are movably mounted. In the example illustrated, the repitch grippers 156 are moveable together (in unison through movement of the EOAT platform 164) between a pick-up position (see FIG. 9) adjacent the unloading location for removing a set of workpieces 170 from adjacent supply retainers 148 at the unloading location, and a drop-off position (see FIG. 12) adjacent the loading location for loading the set of workpieces 170 into adjacent processing retainers 154 at the loading location. The repitch grippers 156 are translatable relative to each other between a pick-up configuration and a drop-off configuration. When in the pick-up configuration, the repitch grippers 156 are spaced apart from each other by the first spacing 158a (FIG. 4). The first spacing 158a corresponds to the first pitch 149 for alignment of the repitch grippers 156 (when in the pick-up position) with corresponding supply retainers 148 at the unloading location to facilitate removal of the set of workpieces 170 from the supply retainers 148. When in the drop-off configuration, the repitch grippers 156 are spaced apart from each other by the second spacing 158b (FIG. 4). The second spacing 158b corresponds to the second pitch 159 for alignment of the repitch grippers 156 (when in the drop-off position) with corresponding processing retainers 154 at the loading location to facilitate loading of the set of workpieces 170 into the processing retainers 154.

In the example illustrated, the repitch robot 162 includes a pair of the repitch grippers 156. In the example illustrated, the repitch grippers 156 are translatable relative to each other between the first and second spacing 158a, 158b along a repitch axis fixed relative to the EOAT platform 164 through operation of one or more servo-drives of the repitch robot 162. In the example illustrated, the repitch axis extends generally parallel with the supply and processing track sections 144a, 150a (and the rows 147, 153 of supply and processing retainers). In the example illustrated, each repitch gripper 156 has a pair of fingers 168 (FIG. 11) moveable relative to each other between a closed position for gripping corresponding workpieces 170 and an open position for receiving and releasing corresponding workpieces 170.

In the example illustrated, the repitch robot 162 is in the form of a pick-and-place robot, and the EOAT platform 164 is movable in a vertical plane perpendicular to the supply and processing track sections 144a, 150a. In the example illustrated, the pick-up position for the grippers 156 is adjustable to any one of a plurality pick-up locations. Each pick-up location is adjacent a corresponding row 147 of the supply retainers 148 of the supply carrier 146 (when at the unloading location) for unloading workpieces from that corresponding row 147 (e.g. after depletion of all workpieces 170 from a preceding row).

Referring to FIG. 5A, in the example illustrated, the repitch station 160a further includes a workpiece presentation system 172 for presentation of the set of workpieces 170 to the repitch grippers 156 to facilitate transfer of the workpieces 170 from the supply retainers 148 to the grippers 156. In the example illustrated the workpiece presentation system 172 is configured to raise the set of workpieces 170 from corresponding supply retainers 148 at the unloading location relative to the supply carrier