Description

FOAM PLUG INSERTING APPARATUS AND FOAM FLUG

INSERTING METHOD

Technical Field

[1] The present invention relates to a robot type foam plug inserting apparatus and a foam plug inserting method, and more particularly to a foam plug inserting apparatus and a foam plug inserting method used in installation of insulators insulating the interior of a cargo tank of a ship. Background Art

[2] In general, several thousand to several tens of thousands of insulation panels are installed on inner walls of a cargo tank of a ship to thermally insulate the cargo tank. The installation work has been done manually.

[3] As illustrated in Fig. 1, in the conventional insulation panel installation work, insulation panels 1 are fixed to an inner hull of the ship by fitting stud bolts thereinto through bolt holes of the insulation panel 1 with predetermined intervals, respectively, while forming a gap therebetween. On the insulation panels 1 having blocks 6 respectively, work areas for installation of the insulation panel 1 are formed in a lattice shape. Further, foam plug holes 3 corresponding to the bolt holes are formed according to corresponding technical standards of a cargo tank.

[4] Cylindrical form plugs 5 each having a recessed hole at a lower end portion thereof are inserted into the foam plug holes 3 formed in the insulation panel 1.

[5] In the technical standards for the cargo tank, there exists a quality regulation by which the depth between the upper end surfaces of the foam plugs 5 and the inlets of the foam plug holes 3 should be with 0 to 2mm.

[6] In the conventional installation of the insulation panels, when the foam plugs are inserted into the foam plug holes, after the foam plugs are moved to the work region, they are inserted into the foam plug holes and the inserted states are controlled according to the quality regulations. However, the installation is performed manually.

[7] Accordingly, recognition of the positions of the foam plug holes into which the foam plugs to be inserted are performed by naked eyes of a worker and insertion of the foam plugs into the foam plug holes are performed manually. Further, a precise insertion process by recognition of the depth or height between the upper end surfaces of the foam plugs 5 and the inlets of the foam plug holes 3 after the insertion of the foam plugs 5 is also performed by naked eyes of a worker.

[8] Therefore, since all the processes are manually performed, depending on the naked eyes of the worker, the accuracy of the work and the uniformity of the quality may be

deteriorated.

[9] Further, when the depth described above is above an allowable value range, much time is consumed to correct it and the work time and the reliability of the quality depends on the skill of the worker. Furthermore, the construction quality of the foam plugs is not uniform and an inconvenient process of reconstruction due to an inferior construction is required and the work efficiency is deteriorated.

[10] Further, in the interior of a cargo tank in which the conventional construction of insulation panels is performed, since the entire wall surfaces of the interior of the cargo tank, i.e. the bottom surface, the inner wall surfaces, the ceiling surfaces are all worked on manually, the fatigue of workers and the possibility of a safety accident can increase and the work efficiency can be deteriorated.

[H]

Disclosure of Invention Technical Problem

[12] Therefore, in view of the above, the present invention provides a foam plug inserting apparatus capable of maximizing the productivity, the workability, and the preciseness by automating manual processes.

[13] It is another object of the present invention to provide a foam plug inserting method capable of assuring the reliability of the quality, of minimizing the error rate, of maximizing the work efficiency, and of preventing a safety accident by automatically inserting foam plugs into foam plug holes while performing mounting and moving operations of a plurality of foam plugs, i.e. insertion members for insulation panels, which are conventionally installed one hundred percent manually.

[14]

Technical Solution

[15] In accordance with one aspect of the present invention, there is provided a foam plug inserting apparatus in which a drive section is installed in a frame section, which includes a plurality of sensors detecting operational situations of the foam plug inserting apparatus, a base plate fixed to the frame section, and a second feeding section in the form of a curved magazine installed in the base plate, to which a plurality of foam plugs are mounted to individually extract and supply the foam plugs. The foam plug inserting apparatus further includes a second insertion section for inserting the foam plugs supplied from the second feeding section into foam plug holes through insertion guides and a control unit mounted to the frame section to control operations of the second feeding section and the second insertion section in correspondence to signals received from the sensors.

[16] In accordance with the other aspect of the present invention, there is provided a foam

plug inserting method including: confirming whether a hole position detection signal for recognizing the positions of foam plug holes into which foam plugs are to be inserted from a foam plug hole recognizing sensor for detecting the plug holes formed in an insulation panel has been received; controlling movement of a drive section to locate insertion guides in the foam plug holes if it is confirmed that the hole position detection signal has been received; extracting the foam plugs loaded to the second feeding section individually, supplying the foam plugs to a second insertion section, and controlling operations of the second feeding section and the second insertion section to insert the foam plugs supplied to the second insertion section into the foam plug holes; determining whether the depth of a step is within a normal value range determined in advance from a received step detection signal for recognizing the depth of the step from a plurality of step confirming sensors for detecting the depth of the step in the foam plug holes into which the foam plugs are inserted; confirming whether the foam plugs are loaded by using a received loaded foam plug detection signal from a loaded foam plug recognition senor if the depth of the step is within the normal value range; and moving the foam plugs for the next operation by driving the drive section if the existence of the loaded foam plug has been confirmed.

[17] It is preferable that an insertion member assembling system (not shown) includes a first module attached thereto or detached therefrom for fitting the flat joints into the insulation panel; a second module attached thereto or detached therefrom for fitting the foam plugs into the insulation panel; a drive part generating a moving force with the first and second modules being mounted to a frame section; and a control unit.

[18] In the description of the present invention, a second feeding section and a second insertion section are elements of the second module.

[19]

Advantageous Effects

[20] In accordance with the foam plug inserting apparatus and method of the present invention, an accurate insertion operation can be performed while maintaining a uniform quality and without any inconvenience of reconstruction, thereby increasing the work efficiency and uniformizing the work quality.

[21]

Brief Description of the Drawings

[22] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[23] Fig. 1 is a perspective view for explaining a conventional insulation panel structure attached to a cargo tank of a ship and a conventional insertion member constructing

structure;

[24] Fig. 2 is an exploded perspective view illustrating a foam plug inserting apparatus and an insertion member assembling system in accordance with an embodiment of the present invention;

[25] Fig. 3 is a perspective view for illustrating an engaged state of the foam plug inserting apparatus and the insertion member assembling system illustrated in Fig. 2;

[26] Fig. 4 is a block diagram of a control unit illustrated in Fig. 2;

[27] Fig. 5 is a perspective view for explaining the structure of a second feeding section illustrated in Fig. 2;

[28] Fig. 6 is a perspective view for explaining the structure of a second insertion section illustrated in Fig. 2;

[29] Fig. 7 is a concept view for explaining the principle of the operation of the second insertion section illustrated in Fig. 6;

[30] Fig. 8 is a flow chart for explaining a foam plug inserting method by the control unit illustrated in Fig. 4; and

[31] Figs. 9 to 18 are perspective views for explaining the operation of the foam plug inserting apparatus illustrated in Fig. 2.

[32]

Mode for the Invention

[33] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[34] Fig. 1 is a perspective view for explaining a conventional insulation panel structure attached to a cargo tank of a ship and a conventional insertion member constructing structure. Fig. 2 is an exploded perspective view illustrating a foam plug inserting apparatus and an insertion member assembling system in accordance with an embodiment of the present invention. Fig. 3 is a perspective view for illustrating an engaged state of the foam plug inserting apparatus and the insertion member assembling system illustrated in Fig. 2. Fig. 4 is a block diagram of a control unit illustrated in Fig. 2. Fig. 5 is a perspective view for explaining the structure of a second feeding section illustrated in Fig. 2. Fig. 6 is a perspective view for explaining the structure of a second insertion section illustrated in Fig. 2. Fig. 7 is a concept view for explaining the principle of the operation of the second insertion section illustrated in Fig. 6. Fig. 8 is a flow chart for explaining a foam plug inserting method by the control unit illustrated in Fig. 4. Figs. 9 to 18 are perspective views for explaining the operation of the foam plug inserting apparatus illustrated in Fig. 2.

[35] First, as illustrated in Fig. 2, a foam plug inserting apparatus 50 in accordance with an embodiment of the present invention includes a second feeding section 500 that is a

foam plug supply device and a second insertion section 600 that is a foam plug inserting device.

[36] The foam plug inserting apparatus 50 in accordance with an embodiment of the present invention is independently moduled in an insertion member assembling system 10 and is attached or detached to and from the insertion member assembling system 10. In the same way, the insertion member assembling system 10 can be applied to automatically insert a flat joint by attaching or detaching the first feeding section and the first insertion section (not shown) in an independently moduled form.

[37] The foam plug inserting apparatus 50 in accordance with the embodiment of the present invention is installed in an outer transverse member 115 on the front side or the rear side of a frame section 100.

[38] The second feeding section 500 mounting a plurality of foam plugs in a curved magazine individually extracts the foam plugs and provides the foam plugs to the second insertion section 600 according to an instruction of a control unit 20 that has been set in advance.

[39] The second insertion section 600 inserts the foam plugs provided from the second feeding section 500 into foam plug holes.

[40] Further, a drive section 200 capable of moving on the entire wall surfaces such as the bottom surface, the ceiling surface, and side wall surfaces of the interior of the cargo tank even when the above-mentioned other modules are mounted to the frame section 100 is installed in the frame section 100.

[41] The drive section 200 includes a first drive module 210 and a second drive module

250 that form a pair on the right and left sides of the frame section 100 and may move along an insulation panel work region or a separate rail (not shown) functioning as a support base with a sufficient load capacity and rigidity.

[42] As illustrated in Figs. 2 and 3, after being positioned on the transverse member 115 on the front portion of the frame section 100, a base plate 501 of the second feeding section 500 is attached or detached by a plurality of engaging unit such as a ball lock and a snap fastener.

[43] The second feeding section 500 has a pair of curved cartridges 510 for mounting and temporarily keeping the plurality of foam plugs. The second feeding section 500 moves the foam plugs by using springs mounted to the curved cartridges 510 respectively, and has second propulsion members 520 connected to the interiors of the curved cartridges 510 to transfer propulsion forces generated from the springs, a pair of robot type grippers 530 extracting the foam plugs arrived at extraction blocks of the curved cartridges 510 by individually gripping the foam plugs, a pivot mechanism 540, and a horizontal movement mechanism 550.

[44] Further, the second insertion sections 600 are engaged with side surfaces of a base

plate 501 of the second feeding section 500 through X-Y free stages 610 respectively. The X-Y free stages 610 are fixed to side surface of the base plate 501 so that they correspond to the foam plug holes arranged in a predetermined interval along the lengthwise direction of a flat panel around the both side edge portions.

[45] The positions of foam plug insertion guides 620 (hereinafter, referred to as insertion guides) connected to the X-Y free stages 610 are set and installed in advance so as to coincide with the foam plug holes of the flat panel at least with respect to the Y-axis direction that will be explained later.

[46] Specifically, while moving the foam plug inserting apparatus in accordance with the embodiment of the present invention by the drive section, the foam plug holes are recognized and stopped. At this moment, the insertion guides 620 are moved to the corresponding foam plug holes respectively so as to insert them into the corresponding foam plug holes.

[47] The second insertion section 600 includes an insertion guide 620, a pusher 630, and a lift cylinder 640. Here, the lift cylinder 640 means a linear drive unit and a linear operation control system lifting and lowering the pusher 630 with a predetermined pressing force by using an electric power source or a pneumatic source. All units including the drive section 200 are controlled by a control unit 20.

[48] As illustrated in Fig. 4, the control unit 20 generally controls a drive or movement of the drive section and foam plug inserting steps 200 as well as the above-mentioned insertion member assembling system.

[49] For this purpose, the control unit 20 is connected to the drive section 200 and the corresponding elements of the foam plug inserting apparatus 50 of the embodiment of the present invention, and controls them in correspondence to a well-known power source supply method and control signal transfer method.

[50] Here, the foam plug inserting apparatus 50 in accordance with the embodiment of the present invention includes the second feeding section and the second insertion section that will be described in detail. The drive section 200 basically has a motor and a mechanical unit for movement thereof. Further, a cross point recognizing sensor 201, a plurality of step confirming sensors 202, a front distance recognizing sensor 203, and a rear distance recognizing sensor 204 connected to the control unit 20 to control the operation of the drive section 200 are installed in the drive section 200. The drive section may further include a potentiometer (not shown) measuring a deformation of a compensation spring to regulate a surface pressing force and various limit sensors (e.g. pressing limit sensors) (not shown) for controlling an excessive operation of a motor or a link.

[51] The cross point recognizing sensor 210 is installed on the front side of one of the drive section 200 or the frame section to which the drive section is mounted. After

detecting a cross point where the insulation panel work regions cross each other, the cross point recognizing sensor 201 can output a cross point detecting signal for recognizing the cross point. Preferably, the cross point recognizing sensor 201 may be an optical sensor (photo sensor) detecting the insulation panel work region. Here, the control unit 20 can recognize the cross point of the insulation panel work region by using the received cross point detecting signal output from the cross point recognizing sensor 201.

[52] A plurality of step confirming sensors 202 are installed in one of the drive section

200 and the frame section. After detecting the depth (relative height difference) of a step between the upper end surfaces of the foam plugs inserted into the foam plug holes and an inlet of the foam plug holes, the step confirming sensors can output step detection signals for recognizing the depth of the step. Preferably, the step confirming sensor 202 may be one of an ultrasonic sensor, a vector sensor, and a laser distance measuring sensor for detecting the depth of the step.

[53] Here, the control unit 20 can recognize the depth of the step by using the received step detection signals output from the plurality of step confirming sensors 202. Further, the control unit 20 can confirm whether the foam plugs have been normally inserted into the foam plug holes by determining whether the recognized depth of the step is within a normal value determined in advance.

[54] The front distance recognizing sensor 203 and the rear distance recognizing sensor

204 recognize an obstacle located on the front or rear side when the drive section 200 moves along the insulation member work region, and transfers a recognition signal to the control unit 20.

[55] Here, the control unit 20 can prevent collision of the drive section 200 with an obstacle by recognizing the obstacle located on the front or rear side.

[56] Foam plug hole recognizing sensors 51, guide insertion confirming sensors 52, guide expansion confirming sensors 53, supply preparation confirming sensors 54, supply completion confirming sensors 55, and loaded foam plug recognizing sensors 56 are installed in the second feeding section and the second insertion section of the foam plug inserting apparatus 50 to transfer signals to the control unit 20.

[57] The foam plug hole recognizing sensors 51 detects the plurality of foam plug holes

(e.g. eight foam plug holes) arranged in a plurality of rows with a predetermined interval on a flat panel (insulation panel). The foam plug hole recognizing sensors 51 generate hole position detection signals representing the positions of the foam plug holes for properly inserting the foam plugs and transmits the hole position detection signals to the control unit 20. Preferably, the foam plug hole recognizing sensors 51 may be optical sensors (photo sensors) for detecting the foam plug holes.

[58] Here, the control unit 20 can recognize the foam plug holes into which the foam

plugs are to be inserted by using the received hole position detection signals output from the foam plug hole recognizing sensors 51. Further, the control unit 20 controls movement of the drive section 200 so that the foam plugs can be inserted into the foam plug holes by a second insertion sections to be described later, thereby properly positioning the frame section and the foam plug inserting apparatus 50 at the locations of the recognized foam plug holes.

[59] The guide insertion confirming sensors 52 output guide insertion confirming detection signals and are used to confirm insertion of insertion guide related elements (e.g. circumferential guide portions) into the foam plug holes. Preferably, the guide insertion confirming sensors 52 may be proximity sensors detecting that the insertion guides are temporarily positioned in the foam plug holes.

[60] Especially, at least two insertion guides are provided in the foam plug forming apparatus 50 to simultaneously guide the foam plugs toward the foam plug holes arranged in a plurality of rows (e.g. two rows). For example, each insertion guide includes a pair of curved circumferential guide portions; arms connected to the outer sides of the circumferential guide portions; an arm operator horizontally operating the arms to be moved close to and far away from the arms; a plurality of guide cylinders lifting the arm operator; and X-Y free stages engaged with upper portions of the guide cylinders.

[61] The guide expansion confirming sensors 53 output guide expansion confirming detection signals, and are used to confirm whether the operations of expanding the insertion guides to the sizes of the inner diameters of the foam plug holes are completed. Preferably, the guide expansion confirming sensors 53 may be proximity sensors for detecting the expansion moment.

[62] Here, the control unit 20 receives the guide insertion confirming detection signals and the guide expansion confirming detection signals that have been output from the guide insertion confirming sensors 52 and the guide expansion confirming sensors 53. The received signals are used to control the operation, stop, and return of the arm operator and the guide cylinders of the second insertion portions used in the insertion or expansion operations of the insertion guides.

[63] The supply preparation confirming sensors 54 can output supply preparation confirming detection signals for confirming that the foam plugs can be supplied to the insertion guides when the insertion guides performed an expansion operation. Preferably, the supply preparation confirming sensors 54 may be proximity sensors installed in the second feeding section to determine that the foam plugs are ready to supply to the insertion guides.

[64] The supply completion confirming sensors 55 can output supply completion confirming detection signals for confirming that the foam plugs were inserted into the

interior spaces of the circumferential guide portions of the insertion guides when the foam plugs are inserted into the interior spaces of the circumferential guide portions of the insertion guides. Preferably, the supply completion confirming sensors 55 may be proximity sensors installed in the second feeding section to determine that the inserted foam plugs were supplied to the insertion guides.

[65] Here, the control unit 20 receives the supply preparation confirming detection signals and the supply completion confirming detection signals that have been output from the supply preparation confirming sensors 54 and the supply completion confirming sensors 55. The received signals are used to control the operation, stop, and return of the elements (e.g. a robot type gripper, a first motor for pivoting the gripper, and a second motor for horizontally moving the gripper) of the second feeding section and the elements (e.g. a lift cylinder for lifting and lowering a pusher) of second insertion section.

[66] When recognizing existence of the foam plugs loaded in advance, the loaded foam plug recognizing sensors 56 can output loaded foam plug recognition signals for confirming existence of the loaded foam plugs. Preferably, the loaded foam plug recognizing sensors 56 may be optical sensors for detecting the loaded foam plugs.

[67] The control unit can recognize that the number of the foam plugs loaded in the foam plug inserting apparatus 50 is more than one by using the received loaded foam plug recognition signals output from the loaded foam plug recognizing sensors 56.

[68] The control unit 20 includes a power supply source 21, an input/output section 22, a central processing unit (CPU) 23, a motion control section 24, and a motor drive section 25.

[69] The control unit 20 controls the operations of the drive section 200 and the foam plug inserting apparatus 50 by using the received corresponding output signals output from the sensors 201, 202, 203, and 204 included in the drive section 200 and the sensors 51, 52, 53, 54, 55, and 56 included in the foam plug inserting apparatus 50.

[70] Then, the output signals output from the encoders of the motors and cylinders provided in the drive section 200 and the foam plug inserting apparatus 50 can be fed back to the control unit 20.

[71] The power supply source 21 performs a function of converting electric power thereof to be suitable for corresponding control unit 20 and related circuits and supplies the electric power to them respectively.

[72] The input/output section 22 receives the corresponding output signals output from the sensors 51 to 56 and 201 to 204 and allows related circuits or the central processing unit 23 of the control unit 20 to recognize the output signals.

[73] The central processing unit 23 can recognize the positions of the foam plug holes into which the foam plugs are inserted by using the received hole position detection signals

output from the foam plug hole recognizing sensors 51 through the input/output section 22 and can output an instruction for inserting the foam plugs into the foam plug holes. Further, the central processing unit can determine whether the depth (height difference) of the step related to the foam plugs inserted into the flat panels are within the normal value determined in advance by using the received step detection signals output from the plurality of step confirming sensors 202. Further, the central processing unit can determine existence of the foam plugs loaded in the foam plug inserting apparatus 50 by using the received loaded foam plug detection signals output from the loaded foam plug recognizing sensors 56. The central processing unit 23 can control the drive section 200 and the foam plug inserting apparatus 50 in correspondence to a predetermined operation algorithm (e.g. foam plug insertion algorithm) when the loaded foam plug detection signals are not received or the depth of the step is not within the normal value.

[74] After receiving drive (operation) request or stop signals and return signals of the motor, the cylinder, the gripper, the arm operator, and so forth that was output from the central processing unit 23, the motion output section 24 outputs a control signal for operating one of the motor, the cylinder, the gripper, the arm operator, and so forth in correspondence to the received signals. Further, the output signals output from the encoders installed in the motor, the cylinder, and so forth are fed back to the motor control section 24 to be transferred to the central processing unit 23.

[75] After receiving motor control signals output from the motion control section 24, the motor drive section 25 amplifies drive currents needed for operations of motors provided in the drive section 200 and the foam plug inserting apparatus 50 and supplies the amplified drive currents to the motors.

[76] The control unit 20 stores control algorithms for a recognition control using various sensors, a motion control using various motors, and an operation control using various cylinders in a memory (not shown) of the control unit as a program, which will be understood by the operational relations, the control, and assembling relations of the present invention. It is preferable that the program stored in the memory may be executed by the central processing unit 23.

[77] Since the execution of the program of the control unit 20 directly corresponds to the operations of the drive section, the second feeding section, the second insertion sections, and so forth, it will be understood by the operational relations of the drive section, the second feeding section, and the second insertion section.

[78] In accordance with the embodiment of the present invention, the foam plugs 5 are continuously inserted into the foam plug holes 3.

[79] As shown in Figs. 2 and 3, in the foam plug inserting apparatus 50, the X-axis direction is the lengthwise direction of the unit including the frame section 100, the Y-

axis direction is the widthwise direction of the unit including the frame section 100, and the Z-axis direction is the heightwise direction of the unit.

[80] Hereinafter, the engagement of the second feeding section 500 and the second insertion section 600 will be described in detail.

[81] As shown in Fig. 5, the second feeding section 500 having the base plate 501 includes a pair of curved cartridges 510, a pair of second propulsion members 520, a pair of robot type grippers 530, a pivot mechanism 540, and a horizontal movement mechanism 550.

[82] The curved cartridges 510 are installed at both ends of the upper side of the base plate 510 by an extraction block 515 and a lever type clamp unit 511.

[83] The curved cartridges 510 temporarily load the foam plugs more inside the curved spaces (e.g. inversed U-shape) than a rectilinear space, therein.

[84] The upper sides of the extraction blocks 515 are opened and are penetratingly connected to ends of the curved cartridge section 510. The other ends of the curved cartridges 510 are closed and are engaged with the second propulsion members 520.

[85] The second propulsion members 520 are moved along the curved spaces of the curved cartridges 510 by using the resilient forces of springs 521 to supply the foam plugs 5 from the other end ends to the one side ends of the curved cartridges 510.

[86] For this purpose, the second propulsion members 520 are guided and moved along the curved spaces of the curved cartridges 510 by a plurality of guide slits 516 provided on the inner and outer surfaces of the curved cartridges 510, a guide shaft member 517 corresponding to a guide mechanism, and a guide plate (not shown).

[87] Especially, preferably, stopper holes 519 for temporarily stopping the second propulsion members 520 to mount the foam plugs 5 are further formed at ends of the guide slits 516 corresponding to propulsion starting points of the second propulsion members 520. Here, the stopper holes 519 are wider than the width of the guide slits 516 to form an engaging step to stop the second propulsion members 520.

[88] On the other hand, the above-mentioned extraction blocks 515 are engaged with ends of the curved cartridges 510.

[89] In Fig. 5, although only one curved cartridge 510 is illustrated for clarity, a pair of curved cartridges 510 are formed substantially symmetrically, i.e. on the right and left sides.

[90] A pair of extraction blocks 515 for the curved cartridges 510 are formed substantially symmetrically, i.e. on the right and left sides.

[91] Each extraction block 515 forms a first through-hole 515a for engagement with the curved cartridge 510, the upper side of which is opened, a second through-hole 515b for an exit for the foam plug 5, the lower side of which is opened, a third through-hole 515c for eliminating interference on a movement path of the gripper 530 by opening

only portions of the side surface and the central side of the bottom surface, and a fourth through-hole 515d opened to check existence of the foam plug 5. The extraction block has a connection end 515e integrally formed along the lengthwise direction of the extraction block 515 at a corner of one side of the extraction block 515.

[92] The connection end 515e of the extraction block 515 is inserted into a connection end insertion hole 512 of the lever type clamp unit 511 and is pressed to be attached or detached.

[93] A plurality of foam plugs 5 are mounted to the curved cartridge 510. The foam plugs located in the interior of the extraction block 515 are extracted by the gripper 530 connected to the control unit right before being discharged from the curved cartridge 510. Then, the foam plugs 5 are withdrawn through the second through-hole 515b of the extraction block 515 which is an exit for the foam plugs sequentially.

[94] A pair of grippers 530 individually grip the foam plugs 5 of the extraction blocks 515 and simultaneously supply the foam plugs toward the insertion guides. For example, each gripper 530 includes a pair of curved grip members 531, a pair of finger members connected to the outer sides of the grip members 532, and a finger operator making the fingers to be moved close to and far away from the fingers, and performs a first operation fl of expanding or contracting the pair of grip members 531 or vice versa to realize the movement of gripping the foam plugs 5 by the extraction blocks 515.

[95] Further, the finger operator 533 of the gripper 530 is engaged with the pivot mechanism 540 and performs a second operation f2 of erecting the foam plugs 5 in the horizontal state or returning the foam plugs 5 as it receives the pivotal force (rotational force) needed for a pivotal operation thereof and is pivoted within a finite rotational angle range.

[96] The pivot mechanism 540 includes a first motor 541 for pivoting the gripper 530 mounted through a motor bracket in the base plate 501, a pivot shaft member 542 connected through a reduction gear of the first motor 541 and having a spline-like shape to guide a linear movement thereof while rotating, spline bosses engaged with both sides of the pivot shaft member 542 so as to receive a rotational force while linearly moving in the pivot shaft member 542, and pivot arms 544 extending from the spline bosses 543, to which the finger operators 533 are mounted.

[97] The pivot arms 544 of the pivot mechanisms 540 are engaged with reciprocal movement members 557 and 558 of the horizontal movement mechanism 550 and perform a third operation f3 for a horizontal movement in a finite stroke range.

[98] The stroke range of the third operation f3 means a horizontal stroke distance between a point where the extraction block 515 grips the foam plugs 5 and a point where the foam plugs 5 are withdrawn from the insertion guide downward.

[99] For this purpose, the horizontal movement mechanism 550 is connected through a

second motor 551 for a horizontal movement of the gripper 530 mounted through another motor bracket on the upper surface of a central portion of the base plate 501 and a power transfer means 552 such as a reduction gear, a drive pulley, a timing belt, a driven pulley, a bearing, a central or side bearing bracket to receive a rotational force, and includes screw shaft members 553 and 554 rotatably supported by a plurality of support brackets and bearings.

[100] Here, the screw shaft members 553 and 554 mean shaft members having screw threads in the form of ball screws. In the screw shaft member, a screw thread is formed so that the right and left portions thereof can be oppositely inclined with respect to the driven pulley at a central portion thereof.

[101] The screw shaft members 553 and 554 are engaged with transfer blocks 555 and 556 in the form of ball screws respectively.

[102] Here, the transfer blocks 555 and 556 are mounted to reciprocal movement members 557 and 558 connected to the pivot arms 544 and provide the right and left grippers 530 with horizontal transfer forces for getting the right and left grippers 530 close to and far away from each other to perform a horizontal transfer such as the third operation f3 of the grippers 530. Here, the reciprocal movement members 557 and 558 can guide smooth horizontal transfers by guide rails 559 connected thereto.

[103] In Fig. 6, although only one second insertion section 600 is illustrated for clarity, a pair of second insertion sections 600 are disposed on the front sides of the robot type grippers of the above-mentioned second feeding section. Then, the second insertion sections 600 are installed in the base plate of the frame section while maintaining the separated distance or disposed interval between the second insertion sections 600 in correspondence to a standard distance between the foam plug holes that was measured when the insulation panels were constructed.

[104] Each second insertion section 600 includes an X-Y free stage 610, an insertion guide 620, a pusher 630, and a lift cylinder 640.

[105] The X-Y free stages 610 are fixed to the base plate of the frame section by using a connection member 611. Within the operation ranges of the X-Y free stages 610, the X-Y free stages 610 provide relative movements to a lower portion of the connection member 611 and all the elements connected thereto. The principle of the operations of the X-Y free stages 610 corresponding to the relative movement will be described in detail with reference to Fig. 7.

[106] The insertion guide 620 comprises a pair of circumferential guide portions 621 and 622 having curved smooth inner surfaces respectively; a pair of arms 623 connected to the outer sides of the circumferential guide portions 621 and 622 respectively; a pair of arm operators horizontally operating the arms to be moved close to and far away from the arms 623; and a plurality of guide cylinders 625 lifting the arm operator.

[107] Here, preferably, an upper portion of the circumferential guide portion has a shape of an expansion pipe and a lower portion thereof has a shape of a circumferential surface corresponding to the inner diameter of the foam plug hole 3. The upper portions of the circumferential guide portions 621 and 622 having the shape of an expansion pipe function as guides to allow easy insertion of the foam plugs and minimize the frictional force with the foam plugs due to the smooth inner surfaces thereof.

[108] The X-Y free stage 610 is engaged with the upper end of a guide cylinder 625. Here, the arm operator 624 is a micro ball screw mechanism or an equivalent thereto, and performs horizontal movements for moving the circumferential guide portions 621 and 622 and the arms 623 to be far away from each other, i.e. a sixth operation f6 for a guide expansion as in Fig. 7A and horizontal movements for moving the circumferential guide portions 621 and 622 and the arms 623 to be close to each other, i.e. a seventh operation f7 for a guide reduction as in Fig. 7B.

[109] The pusher 630 performs a fourth operation f4 of being lifted and lowered by the lift cylinder 640 in the upward and downward direction (i.e. the Z-axis direction).

[110] The fourth operation f4 of the pusher 630 performs a function of inserting the foam plugs into the foam plug holes of the insulation panel as the foam plugs loaded inside of the circumferential guide portions 621 and 622 of the insertion guide 620 are pushed downward.

[I l l] An upper portion of the pusher 630 is engaged with the lift cylinder 640 and a lower portion thereof has a circular disk-shaped pressing plate 631 capable of pressing the foam plugs. Here, it is preferable that the diameter of the pressing plate 631 has a relatively small size as compared with the diameter of the pair of circumferential guide portions 621 and 622 that have a cross-sectional shape close to a circular layout.

[112] As illustrated in Fig. 7, the pair of circular guide portions 621 and 622 can perform the sixth operation f6 for guide expansion or the seventh operation f7 for guide reduction by the arms 623 and the arm operator 624.

[113] The base plate 501 is fixed to the frame section in accordance with the present invention and functions as a support base for the X-Y free stages 610.

[114] Since an upper portion of the X-Y free stage 610 is fixed to the base plate 501, a lower portion thereof can be relatively moved in the X-Y plane, with the base plate 501 functioning as a support base.

[115] Fig. 7 A shows the initial operational state of the insertion guide 620. Here, the circumferential guide portions 621 and 622 of the insertion guide 620 get close to each other by the arm 623 and the arm operator 624 to have a cross-sectional shape close to an ellipse. As a result, the circumferential guide portions 621 and 622 have a size smaller than the foam plug holes 3 so as to be inserted into the foam plug holes 3.

[116] Referring to Fig. 6, in this state, the entire insertion guide 620 including the circum-

ferential guide portions 621 and 622 performs the fifth operation f5 for being lifted and lowered by the guide cylinders 625.

[117] Referring to Fig. 7, the lower portions of the circumferential guide portions 621 and 622 are inserted into the foam plug holes 3. Especially, the insertion method eliminates the bothersomeness of precisely finding the centers cl of the foam plug holes 3 that can be substantially different from each other in the field and of coinciding the centers Cl of the foam plug hole with the centers c2 of the circumferential guide portions 621 and 622.

[118] Further, in spite of the field condition such as the discrepancy of the centers, the X-Y free stages 610 help portions of the circumferential guide portions 621 and 622 to be inserted into the foam plug holes 3.

[119] Fig. 7B illustrates the state of the insertion guide 620 after the operation thereof. The circumferential guide portions 621 and 622 inserted into the foam plug holes 3 get separated from each other by the arm 623 and the arm operator 624 and are expanded so as to have a cross-section close to a circular layout.

[120] Accordingly, the outer peripheral surfaces of the circumferential portions 621 and 622 are adhered to the inner peripheral surfaces of the foam plug holes 3.

[121] Especially, as in Fig. 7 A, the difference between the centers cl of the foam plug holes 3 and the centers c2 of the circumferential guide portions 621 and 622 is eliminated by the passive movements P of the X-Y free stages 610 in correspondence to the sixth operation f6 for guide expansion so that the centers cl and c2 can coincide with each other.

[122] Therefore, in the foam plug inserting algorithm of the present invention, even when it is programmed that the foam plugs can be inserted with respect to the centers c2 of the circumferential guide portions 621 and 622, there occurs no problem in the foam plugs being accurately inserted with respect to the centers cl of the foam plug holes 3.

[123] Hereinafter, the foam plug inserting method controlled by the control unit will be described with reference to Fig. 8.

[124] As illustrated in Fig. 8, the control unit confirms whether a hole position detection signal for recognizing the positions of foam plug holes into which foam plugs are to be inserted from a foam plug hole recognizing sensor for detecting the plug holes formed in an insulation panel has been received (SlO).

[125] Then, when the control unit receives and confirms the hole position detection signal output from the foam plug hole recognizing sensor, it positions the insertion guide at the foam plug holes by operating the drive section (sl3). Then, the circumferential guide portions of the insertion guide are in the state of Fig. 7A.

[126] After being lowered by the guide cylinders, the circumferential guide portions of the insertion guide perform the fifth operation as in Fig. 7B. In this case, the centers of the

foam plug holes and the circumferential guide portions are coincided with each other and the operation corresponds to the step S 13 (second step in the claims), which will be described in detail with reference to Figs. 9 to 11.

[127] On the other hand, if the control unit has not received the hole position detection signal output from the foam plug hole position recognizing sensor, the control unit can return to the step SlO of confirming the reception of the hole position detection signal by continuously operating the drive section (S15).

[128] Further, the control unit individually extracts the foam plugs mounted to the feeding section and supplies the extracted foam plugs toward the second insertion section, and then allows the supplied foam plugs to be inserted into the foam plug holes by the second insertion section (sl7).

[129] The step S15 (third step in the claims) will be described in detail with reference to Figs. 12 to 18.

[130] Then, it is determined whether the depth of a step is within a normal value determined in advance by using a received step detection signal for recognizing the depth of the step from a plurality of step confirming sensors for detecting the depth of the step in the foam plug holes into which the foam plugs are inserted

[131] If the depth of the step is not within the normal valve determined in advance, the control unit converts the mode to a manual mode in which the operation of the entire insertion member assembling system is temporarily stopped and a user can directly control the operation of the system.

[132] If the depth of the step is within the normal value, existence of the loaded foam plugs is confirmed by using a received loaded foam plug detection signal for recognizing the loaded foam plugs from a loaded foam plug recognizing senor for recognizing the existence of the loaded foam plugs (S23).

[133] When confirming the existence of the loaded foam plugs, the control unit moves the drive section for the following works by driving the drive section (S25).

[134] During the moving of the drive section, the control unit returns to the step SlO of confirming whether a hole detection signal output from the foam plug hole recognizing sensor for recognizing other foam plug holes has been received.

[135] Meanwhile, even when the control unit does not confirm the existence of the loaded foam plugs, it may temporarily stop the operation of the entire insertion member assembling system and converts the mode to a manual mode capable of allowing a user to directly control the system (S21).

[136] Hereinafter, the operation of the foam plug inserting apparatus in accordance with the embodiment of the present invention will be described with reference to the foam plug inserting method, which is performed by the control section.

[137] That is, during a movement using the drive section, the control unit in accordance

with the embodiment of the present invention sequentially performs various steps while recognizing the foam plug holes.

[138] As illustrated in Fig. 9, the step of properly positioning the insertion guide is performed.

[139] In the step of properly positioning the insertion guide, the operation of the drive section is performed to a predetermined position by the control unit and the foam plug hole recognizing sensor so that the entire frame section in which the foam plug inserting apparatus is installed performs move and stop operations.

[140] In this case, the circumferential guide portions 621 and 622 of the insertion guide

620 of the second insertion section 600 mounted to the frame section are positioned on the vertical upper sides of the foam plug holes.

[141] Further, the pair of grippers 530 of the second feeding section 500 exist in the initial state of gripping the foam plugs 5 in the extraction block 515 so as to individually extract the foam plugs 5 from the corresponding curved cartridges 510.

[142] Thereafter, as illustrated in Fig. 10, the step of lowering the insertion guide is performed.

[143] In the step of lowering the insertion guide, as the guide cylinder 625 is lowered and stopped as in the fifth operation f5, lower portions of the circumferential guide portions

621 and 622 of the insertion guide 620 of the second insertion section 600 located on the vertical upper sides of the foam plug holes are inserted into the corresponding foam plug holes.

[144] Thereafter, as illustrated in Fig. 11, the step of centering the insertion guide is performed.

[145] In the step of centering the insertion guide, when the sixth operation in which lower portions of the inserted circumferential guide portions 621 and 622 are expanded is completed, as mention above through Fig. 7, the centers of the foam plug holes and the centers of the circumferential guide portions 621 and 622 coincide with each other and the foam plugs 5 can be accurately inserted into the foam plug holes through the circumferential guide portions 621 and 622.

[146] Thereafter, as illustrated in Fig. 12, the step of extracting the foam plugs is performed.

[147] In the step of extracting the foam plugs, the horizontal movement mechanism 550 moves the grippers 530 and the foam plugs 5 by a 3- lth operation f3-l so that the grippers 530 can pull the foam plugs waiting in the extraction blocks 515.

[148] In this case, the second propulsion members 520 using the springs 521 of the curved cartridges 510 move the rest foam plugs and new foam plugs are supplied to and loaded into the extraction blocks 515.

[149] Thereafter, as illustrated in Fig. 13, the step of pivoting the foam plugs is performed.

[150] In the step of pivoting the foam plugs, the first motor 541 for pivoting the grippers

530 of the pivot mechanism 540 rotates the pivot shaft member 542. In this case, as the spline boss 543, the pivot arms 544, and the grippers 530 that are engaged with the pivot shaft member 542 are pivoted together with the second operation f2, the foam plugs 5 in the horizontal state are erected vertically.

[151] Thereafter, as illustrated in Fig. 14, the step of properly positioning the foam plugs is performed.

[152] In the step of properly positioning the foam plugs, the horizontal movement mechanism 550 moves the grippers 530 and the foam plugs 5 by a 3-2th operation f3-2, so that the erected foam plugs 5 can be properly positioned on the vertical upper sides of the circumferential guide portions 621 and 622 of the insertion guide 620.

[153] The step of properly positioning the foam plugs will be clearly understood through Fig. 15.

[154] As illustrated in Fig. 15, the foam plugs 5 are properly positioned on the vertical upper sides of the circumferential guide portions 621 and 622 and the circumferential guide portions 621 and 622 and the foam plug holes are coincided with each other. In this state, if the pusher 630 and the lift cylinder 640 pushes down the foam plugs 5, the foam plugs 5 can be accurately inserted into the foam plug holes.

[155] Therefore, as illustrated in Fig. 16, the step of inserting the foam plugs is performed.

[156] In the step of inserting the foam plugs, as the pusher 630 operated by the lift cylinder 640 is lowered through a space Ql (refer to Fig. 5) between the pair of grip members

531 of the gripper 530 and a space Q2 (refer to Fig. 6) between the circumferential guide portions 621 and 622 of the insertion guide 620 without interference and then is pressed, the foam plugs 5 are positioned in the foam plug holes.

[157] Here, the space Ql between the grip members 531 is illustrated in Fig. 5 and the space Q2 between the circumferential guide portions 621 and 622 is illustrated in Fig. 6.

[158] Thereafter, as illustrated in Fig. 17, the step of returning the insertion guide is performed.

[159] In the step of returning the insertion guide, the guide cylinder 625 is lifted and stopped as in the fifth operation f5 instead of the pusher maintaining the lower state.

[160] In this case, the foam plugs 5 are maintained in the foam plug holes by the pusher

630 even when the frictional force is applied to the foam plugs, instead of the circumferential guide portions 621 and 622 being withdrawn from the foam plug holes.

[161] Finally, as illustrated in Fig. 18, the step of returning the pusher is performed.

[162] In the step of returning the pusher, the pusher 630 positioned at upper portions of the foam plugs 5 is moved upward by the lift operation of the lift cylinders 640 and is returned to the original position.

[163] Thereafter, the elements are returned to their original positions by reversely performing the above-mentioned steps. The steps in Figs. 9 to 18 can be repeated until the stop of the system or the conversion to the manual mode.

[164] Therefore, in accordance with the foam plug inserting apparatus and method of the present invention, the centers of the insertion guide and the foam plug holes can be simply and easily coincided with each other by using the X-Y free stages, the guide cylinders, the arm operator, a pair of circumferential guide portions, thereby accurately inserting the insertion guides into the foam plug holes and thus promptly inserting the foam plugs into the foam plug holes.

[165] Further, in accordance with the foam plug inserting apparatus and method of the present invention, an accurate insertion operation can be performed while maintaining a uniform quality and without any inconvenience of reconstruction, thereby increasing the work efficiency and uniformizing the work quality.

[166] While the invention has been shown and described with respect to the embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined in the following claims.

[167]