CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 62/349,453, filed June 13, 2016. The disclosure of the above application is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a tool assembly and a method for automated clip installation.

BACKGROUND OF THE INVENTION

Automotive components are attached in any number of ways, such as with adhesive and/or fasteners, e.g., screws, rivets, etc. Attachment clips such as plastic molded clips generally are used in automotive parts to provide the attachment of trim pieces, panels or other parts to the support structure of the vehicle. There are various types of clips and applications in automotive. One known type of clip attaches (e.g., slid in or otherwise attached) to a feature commonly called a "doghouse". Typical clips include a circular profile portion(s) or is a winged clip or a radial clip. Since clips and parts can vary, virtually all applications require tolerance control of the attachment.

Whatever the clip design is, it must be picked up so that it can be installed on the part. There are no known automated approaches. Common non-automated solutions for picking up plastic clips use mechanical lock mechanisms of some sort to pick up each clip. Most of these solutions are complicated and are in need of constant adjustment due to clip variations.

Existing manual insertion processes for attachment clips to parts, such as rocker panels for vehicles, is time consuming and not economically friendly. Additionally, the potential for quality errors, such as missing or unseated clips, is very high.

It is therefore desired to have an automated attachment clip installation system and method for installing clips that is ergonomic, repeatable, and meets quality requirements.

SUMMARY OF THE INVENTION

The present invention generally relates to a clip installation tool system and method including a magazine for aligning a plurality of clips and clip end of arm tooling for picking up the clips. The magazine has a plurality of openings, such as sloted openings, each holding a loaded clip. A servo cylinder is used to stop the magazine in locations at predetermined intervals for spacing the clips into each respective opening, such as to align the clips in a row in the magazine. The clip end of arm tooling has at least one body or manifold with a plurality of inlet/outlet portions or "pegs" or "cylinders". The pegs are generally cylindrical. The distal end of each peg is shaped for picking up and holding a respective clip, e.g., mechanically holding each clip. The proximal end of each peg is operably connected to the body. The clip end of arm tooling picks up the desired number of clips at once (one or more clips depending on the application) from the magazine and vacuum generation to the peg(s) assists with holding the clip(s). The vacuum applied to the pegs helps compensate for clip variations, assists in holding the clips, assists with sensing (e.g., in verifying a clip is present), and eliminates dropping of the clips prior to desired placement. Once the clip(s) is/are installed or otherwise put in position, air blowoff to the specific peg(s) is applied to insure foam or other clip structures stay in place on the clip and to insure the clip is removed from the peg(s) and stay in the desired position(s). After all clips are placed, the vacuum is cycled to verify all clips were removed from the pegs.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

Figure 1 is a front elevation view of a magazine and clip end of arm tooling of a clip installation tool system next to a plurality of clips to be picked up, in accordance with one embodiment of the present invention;

Figure 2 is a front elevation view of the clip end of arm tooling engaging the clips in position for removing the plurality of clips from the magazine, in accordance with the present invention;

Figure 3 is a bottom view of the clip end of arm tooling depicted for showing the tooling holding the clips, according to the present invention; Figure 4 is a perspective view of a magazine and a servo cylinder and feeder device of a clip installation tool system before clips are loaded to the magazine, in accordance with another embodiment of the present invention;

Figure 5 is a perspective view of a magazine and a servo cylinder and feeder device of a clip installation tool system having a plurality of clips loaded to the magazine, in accordance with the present invention;

Figure 6 is perspective view of the clip installation tool system with a peg in position to pick up one clip from the magazine, according to the present invention;

Figure 7 is perspective view of the clip installation tool system that is rotated to bring a plurality of pegs in position for picking up a plurality of clips from the magazine, according to the present invention;

Figure 8 is an enlarged perspective view of the clip installation tool system to move a plurality of clips along the slot of the magazine to remove the clips from the magazine, according to the present invention; and,

Figure 9 is perspective view of the clip installation tool system that is rotated to bring another peg into engagement with another clip to retrieve the clip from the magazine, according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

Referring to Figures 1 -3 generally, in accordance with the present invention, there is provided a clip installation tool system shown generally at 10 including a clip end of arm tooling shown generally at 12 and at least one clip holding device 14 or "magazine" that holds a plurality of clips 16 simultaneously. The clip end of arm tooling 12 has at least one clip loading device 18 or "peg" or " inlet/outlet portions" operable for picking up at least one clip 16 at a time, preferably, picking up a plurality of clips 16 at the same time. The clip loading device 18 preferably picks up a plurality of clips 16 and delivers the clips to a part for assembly, e.g., in the manufacture of an automotive component/assembly. The magazine 18 is preferably an enlongated part with a plurality of lateral openings, preferably, slots, to slidably receive the clips 16 and retain the clips 104 for retrieval by the pegs 16. The pegs 18 are generally cylindrical with an opening sized to retreive and hold the clip 16 on the end of the peg 18. When the pegs 16 are brought into engagement with the clips 18, a vaccum is applied to hold and detect the clip 18. The pegs 16 are moved as a unit to slide the clips 18 laterally out of the elongated opening. Thus, the system 10 can retrieve a plurality of clips 18 at the same time, which is a significant advantage in cycle time.

Referring to Figures 4-9 generally, in accordance with the present invention, there is provided a clip installation tool system shown generally at 100 including at least one magazine shown generally at 102 for aligning a plurality of clips 104 and at least one clip end of arm tooling ("EOAT", shown generally at 106) for picking up a predetermined amount of the clip 104 at once. The magazine 102 has a plurality of openings 108, which shape and dimensions correlate with the particular clip depending on the application. While the figures illustrate openings sloted along the edge of the magazine, wherein each opening holds a loaded clip, it is within the scope of the present invention that other configurations are contemplated without departing from the scope of the present invention.

At least one servo cylinder device 1 10 (or any other or additional suitable device, actuator, motor, ECU, etc, and combinations) is utilized and the magazine 102 is stopped at predetermined intervals for spacing the clips 104 into each respective opening 108, such as to align the clips in a row in the magazine 102. A clip feeder shown generally at 1 12, e.g., a bowl feeder, is operably attached adjacent to the magazine 102 and servo cylinder 1 10 for feeding clips 104 to the magazine 102. With the use of the magazine 102 design and servo cylinder 1 10 to operably stop the magazine, the clips are aligned in a row (or any other predetermined desired pattern and intervals) for the clip installation process, allowing a plurality or clips to be picked up at once (or just one whenever desired). Thus, the magazine 102 is used to get the clips 104 in position for the process (with the servo cylinder 1 10 and clip feeder 1 12 attached. A drive mechanism advances the linearly magazine 102 for loaded clips 104 into the openings 108.

The EOAT 106 has at least one body 1 14 or manifold with a plurality of inlet/outlet portions or "pegs" 1 16. Preferably, these pegs are generally cylinder shaped with an inlet/outlet port at the distal end, and are operably coupled at the proximal end to the body 1 14. Optionally, one or more additional peg 1 18 is provided on one or both ends of the body (e.g., substantially similar design and function to the pegs 1 16). The distal end of each peg 1 16 is operably shaped for picking up and holding a respective clip 104, e.g., mechanically holding each clip. In one embodiment, the peg 1 16 is generally round with a specifically shaped tip to utilize the clip 104 mechanically. By way of example, the tip of the peg 1 16 has a smaller diameter portion used for mechanically holding the clip 104

Vacuum is used to hold and detect each clip on the EOAT 106. By adding this vacuum generation to the peg 1 16, there is compensation for clip 104 variation, assistance in holding the clip 104, sensing, and elimination of dropping clips 104. At least one vacuum line 120 is operably connected to the body 1 14 and to a vacuum pump to provide the predetermined vacuum. A control unit controls the vacuum pump. In a preferred embodiment, the pump is a smart pump so that feedback is used for sensing the clip 104 on each peg 1 16.

The EOAT 106, moved by a robotic arm 122, picks up the desired number of clips 104 at once (one or more clips 104 depending on the application) from the magazine 102 and vacuum generation to the peg(s) 1 16 (and 1 18 when used) assists with holding the clip(s) 104 in the cylinders 1 16,1 18. The vacuum applied to the pegs 1 16 helps compensate for clip variations, assists in holding the clips, assists with sensing (e.g., in verifying a clip is present), and eliminates dropping of the clips prior to desired placement. Once the clip(s) 104 is/are installed or otherwise put in position, air blowoff to the specific peg(s) 1 16,1 18 is applied to insure foam or other clip structures stay in place on the clip 104 and to insure the clip 104 is removed from the peg(s) and stay in the desired position(s). After all clips 104 are placed, the vacuum is cycled to verify all clips 104 were removed from the pegs 1 16,1 18. The on/off peg vacuum and on/off peg blow off is specifically delivered to each of the pegs 1 16,1 18 individually, in a preferred embodiment.

In a preferred embodiment, the servo cylinder 1 10 includes a reciprocatable block 124 with at least one narrower portion 126 that fits within a respective groove 128 formed in the feeder 130. The block 124 reciprocates toward/away from the magazine 102 in intervals corresponding with advancement of the magazine 102 to align each opening 108 of the magazine in series to the open end of the groove 126. When the block 124 is pulled away from the magazine 102, a clip 104 is operably fed automatically into the groove 126. At least one clip 104 is fed to the groove 128 at a time. The magazine 102 is advanced to align an empty opening 108 with the open end of the groove 126 adjacent the magazine opening 108. The block 124 then moves toward the magazine 102 pushing the clip 124 along the groove 126 using the narrower portion 126 and the clip 104 is pushed into the opening 108. The block 124 is withdrawn and the next clip 104 is loaded into the groove 126. The process is repeated until the predetermined number of clips 104 are loaded into the magazine 102. The EOAT 106 is then used to pick up all of the clips 104 held in the openings 108. After the clips 104 are picked up, the EOAT 106 rotates to a final assembly cell or station to unload the clips 104 into predetermined areas of the part being manufactured.

Because the magazine 102 has a plurality of aligned clips 104, multiple pegs 1 16 are able to be placed in a line (e.g., more or less than 8 or 9 pegs), which reduces the time it takes to pick up the clips 104 needed for the part being assembled, e.g., by picking all 8 clips 104 up at one time. Assembly with multiple clips 104 in line allows for reduced pick up time.

Use of nylon (plastic) for the body for rigidity, wear, and reduced weight is preferred, e.g., of the peg 1 16,1 18, peg tips, and/or body 1 14.

Once the clip 104 is put in position, blow off is supplied through the peg 1 16. This air blow off is used to ensure foam, or any alternative or additional component(s) of the clip, are kept from sticking to the peg 1 16, and that the clip is removed from the peg 1 16. In a preferred embodiment, multiple clips 104 are picked up at once (one per peg), each clip 104 held by vacuum passing through the EOAT 106, and at least one clip 104 is put in place on the part, and, upon placement on that part, air blow off is supplied through the EOAT 106 to that at least one peg that had held the respective clip 104. Blow off is supplied to at least one peg at a time. Depending on the particular application, to a plurality of pegs 1 16.

According to an embodiment of the present invention, the plurality of pegs 1 16 are provided inline on the body 1 14 of the EOAT 106 and at least one additional peg 1 18 is provided on each end of the body 1 14 of the EOAT 106. A plurality of clips 104 are loaded into a feeder 1 12, the clips 104 are then loaded to the magazine 102 (e.g., 1 1 clips 104) from the feeder 1 12, the arm 122 moves the EOAT 106 into position such that a peg 1 18 is over a clip 104, the clip 104 is picked up by the peg 1 18 as the vacuum is turned on, the EOAT 106 moves to slide the clip 104 laterally out of the opening 108, the EOAT 106 is rotated and moved to bring pegs 1 16 over more clips 104 in the magazine 102, a plurality of clips 104 (e.g., 9 clips) are picked up at the same time by pegs 1 16 as the vacuum is turned on, the EOAT 106 moves to slide the clips 104 out of the openings 108, the EOAT 106 is rotated and moved again to be over more clips 104 in the magazine 102, at least one clip 104 is picked up by the other of the end pegs 1 18 as the vacuum is turned on, EOAT 106 moves to the clips 104 out of the openings 108, e.g., lateral openings. Now with all the clips 104 retrieved from the magazine 102 and held by the pegs 1 16,1 18, the EOAT 106 is operably moved to the part to which the clips 104 are to be installed (and the clips 104 are operably installed to the part), at least one clip 104 is put in place on the part as blow off is applied to the respective peg(s) 1 16 or 1 18, clip 104 placement is repeated until all the clips 104 are removed from the EOAT 106, optionally, vacuum is applied through all the pegs 1 16,1 18 to verify no clips remain on the EOAT 106.

The invention inserts attachment clips reliably with a high degree of precision. Additionally, the machine "self checks" or poka-yokes itself to determine if all clips are present and properly installed before releasing the part. The machine is much faster and more reliable than a human operator.

The tooling and process automatically and repeatedly installs clips to the proper depth and provide an electronic poka-yoke to verify that clips where properly installed.

It is understood that any other type of fastener is contemplated, including, but not limited to, clips, threaded fasteners, winged clips, radial clips, spring steel nuts, self- tapping fasteners, and combinations thereof are contemplated without departing from the scope of the present invention. It is further contemplated that installation is to molded-in doghouse or heat staked, or any other suitable predetermined attachment without departing from the scope of the present invention.

The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the essence of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.