THEREWITH

Priority Documents

[0001] The present application claims priority from Australian Provisional Application No. 2017904110 titled "Carousel with object locating bays for buffering in a conveying operation, and carousel with object locating bays and a turret and boom associated therewith" and filed on 11 October 2017, the content of which is hereby incorporated by reference in its entirety.

Background of the Invention

[0002] The present invention relates to machines for performing operations and to conveyance of objects and materials in such machines. The invention has particular application in automated equipment for additive construction.

Description of the Prior Art

[0003] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

[0004] In this specification the word "brick" is intended to encompass any building element such as a brick or block, to be placed during the construction of a building or wall or the like. Further, it is anticipated that the conveyance of items other than bricks is contemplated by the invention.

[0005] The applicant has described a machine for conveying objects which is incorporated into an automated brick laying machine, which is the subject of international patent application PCT/AU2017/050730. A boom for conveying objects such as bricks is supported on a turret which is mounted to a base. The turret is rotatable about a vertical axis so that the boom may sweep radially about the base. The boom includes at least one shuttle which locates on a track which runs along the boom. The shuttle has a gripper (hereafter "boom shuttle gripper") to grip and convey an object along the boom. Where the boom has telescoping boom elements, there is one shuttle on a track in each element of the boom (that is one shuttle in the main boom element and one shuttle in each telescoping element), and the object is passed from shuttle to shuttle to move the object out along the boom.

[0006] The turret has a shuttle with a gripper (hereafter "turret shuttle gripper") which grips an object and is mounted on a vertically extending track, so that the object can be transported from where it is placed at the bottom of the turret, up the turret, to be presented to a pivoting gripper mounted on a pivot with a horizontal axis. The pivoting gripper can rotate about its horizontal axis to align with the turret shuttle gripper, to receive the object from the turret shuttle gripper, and rotate to align with the boom shuttle gripper, to transfer the object from the turret to the boom.

[0007] As the turret rotates relative to the base, the vertically extending track with its turret shuttle rotates with it. This gave rise to the provision of a carousel located around the base of the turret, and rotatable therearound, so that an object could be placed on the carousel, and the carousel rotated to the correct angular position to present the object to the turret shuttle. The carousel described in PCT/AU2017/050730 had a gripper (hereafter "carousel gripper") which the object was placed into and gripped. The gripper was mounted to the carousel about a horizontal pivot axis located radially toward the base of the turret, so that the carousel which could pivot about the horizontal axis to rotate the object (a brick) upward and toward the turret to present it to be gripped by the turret shuttle gripper.

[0008] It should be noted that the terms horizontal and vertical are relative. If the above described arrangement was to be deployed in space in zero gravity conditions for moving objects from one location out along a boom to another location, whether a particular orientation is vertical is moot.

[0009] In an arrangement for transporting objects from a base and out along a telescoping boom, there may be a procession of objects being placed on the carousel and transferred out along the boom. Where the objects differ from each other, such as in matters of shape and configuration, where they are presented in a particular order to assemble a structure, if damage occurs to one of the objects after it has been placed on the turret shuttle, this may necessitate the objects being reversed, which can be back from the boom or even a telescoping stick, to the carousel and thence to be stacked so a replacement for the damaged object can be provided, and then the stacked objects returned to the carousel and the boom in the correct order, for the operation to continue.

[0010] It would be advantageous to provide improved utility in such an arrangement.

[0011] It is against this background, and the problems and difficulties associated therewith, that the present invention has been developed.

Summary of the Present Invention

[0012] In one broad form, an aspect of the present invention seeks to provide a machine for conveying objects, the machine including:

a) a base;

b) a turret mounted to the base for rotation about an axis, the turret including:

i) a turret mounted track extending between the base and a position proximate a boom mounting; and,

ii) a turret shuttle with a gripper to grip an object, the turret shuttle mounted on the turret mounted track;

c) a boom mounted to the turret at a position located away from the base, the boom extending away from the turret, whereby rotation of the turret sweeps the boom radially about the axis, the boom including:

i) a boom mounted track extending therealong; and,

ii) a boom shuttle with a gripper to grip an object, the boom shuttle mounted to the boom mounted track for controlled movement therealong, wherein when the turret shuttle and the boom shuttle are located proximate to the boom mounting, an object may be transferred therebetween; and,

d) a carousel located proximal to the base extending around the turret and rotatable about the axis, the carousel having a plurality of object bays in which may be located an object, the carousel being controllably rotatable about the axis to locate any of the object bays proximal to the turret mounted track for transfer of an object between the object bay and the turret shuttle.

[0013] In one embodiment, each of the object bays includes a gripper to grip an object.

[0014] In one embodiment, the machine includes a loading gripper arranged to load an object into any one of the object bays, at a predetermined position on the base relative to the turret. The carousel will then rotate if necessary to align the object bay concerned, with the turret mounted track, so that the gripper of the turret shuttle can pick up the object from the object bay.

[0015] In one embodiment, the turret shuttle gripper is arranged with an offset pivot to rotate the turret shuttle gripper radially outwardly toward any one of the object bays in which position the turret shuttle gripper may grip an object before rotating the turret shuttle gripper and gripped object to a position extending along the axial extent of the turret, in which position of the turret shuttle gripper, the turret shuttle gripper may transfer the object to the boom.

[0016] In one embodiment, the boom is mounted to the turret about a boom mounting axis extending transversely to the axis, allowing the boom to be rotated in order to adjust a pitch of the boom. Where the axis is vertical the boom will sweep radially horizontally when the turret is rotated, and the transverse axis will be horizontal, allowing the boom to be raised and lowered arcuately thereabout.

[0017] In one embodiment, a transfer gripper is located rotatably about the boom mounting axis and is aligned to receive the object from the turret shuttle gripper and transfer the object to the boom shuttle for conveyance out along the boom.

[0018] In one embodiment, the boom has telescoping boom elements, wherein each of the telescoping boom elements has a telescoping boom element mounted track extending therealong, and a shuttle with gripper to grip an object, the shuttle being mounted on the telescoping boom element mounted track for controlled movement therealong. [0019] In one embodiment, the boom has a stick pivotally mounted at a remote end thereof, the stick having a stick mounted track extending therealong, and a stick shuttle with gripper to grip an object, the stick shuttle being mounted on the stick mounted track for controlled movement therealong.

[0020] In one embodiment, the stick has telescoping stick elements, wherein each of the telescoping stick elements has a telescoping stick element mounted track extending therealong, and a shuttle with gripper to grip an object, the shuttle being mounted on the telescoping stick element mounted track for controlled movement therealong.

[0021] In one embodiment, the number of object bays on the carousel is equal to or greater than the number of shuttles in the machine. The number of shuttles may include the turret shuttle, boom shuttle, and stick shuttle, if present.

[0022] In one embodiment, the carousel is mounted to the turret so as to be rotatable therewith whilst also being controllably rotatable relative to the turret.

[0023] In one embodiment, the object is a block.

[0024] In one embodiment, the size and/or configuration of the block is variable.

[0025] In another broad form, an aspect of the invention seeks to provide a carousel for use in a conveying system including a conveyer carrying a plurality of objects in an assembly line, the carousel located adjacent to the conveyor and having a plurality of object bays in which an object may be located, the carousel being controllably rotatable about an axis to locate any of the object bays proximal to a robotic gripper for controlled transfer of an object between the object bay and the conveyor.

[0026] In one embodiment, each of the object bays includes a gripper to grip an object.

[0027] In one embodiment, objects are transferred from a loading gripper to the conveyer via the carousel. [0028] In one embodiment, the loading gripper is configured to load an object into any one of the object bays and the robotic gripper is configured to unload an object from the carousel to the conveyer and optionally reload an object into any one of the object bays.

[0029] In another broad form, an aspect of the invention seeks to provide a machine for conveying objects having a base with a turret mounted to said base for rotation about an axis, said turret having a boom mounted to said turret at a position located away from said base, said boom extending away from said turret, where rotation of said turret sweeps said boom radially about said axis; said turret having a turret mounted track extending between said base and said position, and a turret shuttle with gripper to grip an object, said turret shuttle being mounted on said turret mounted track; said boom having a boom mounted track extending therealong, and a boom shuttle with gripper to grip an object, said boom shuttle being mounted on said boom mounted track for controlled movement therealong; where when said turret shuttle and said boom shuttle are located proximal to said position, an object may be transferred therebetween; said machine having a carousel located proximal to said base extending around said turret and also rotatable about said axis; wherein said carousel has a plurality of object bays in which may be located an object, said carousel being controllably rotatable about said axis to locate any of said object bays proximal to said turret mounted track for transfer of an object between said object bay and said turret shuttle.

[0030] In yet a further broad form, an aspect of the invention seeks to provide in a conveyor carrying a plurality of objects in an assembly line, a carousel located adjacent to said conveyor, said carousel having a plurality of object bays in which an object may be located, said carousel being controllably rotatable about said axis to locate any of said object bays proximal to a robotic gripper for controlled transfer of an object between said object bay and said conveyor. The objects may be carried on the conveyor in an assembly line. Where the processing of the objects prior to their reaching the carousel takes some time, the carousel acts as a buffer, continuing to despatch prior-located objects for downstream processing.

[0031] In one embodiment, the carousel intersects said conveyor and a loading gripper is provided, arranged to load an object into any one of said object bays, and said robotic gripper may unload an object from said carousel to said conveyor, and optionally reload said object into any one of said object bays. The carousel may rotate if necessary to align the object bay loaded with the required object, so the required object can be loaded by said robotic gripper to said conveyor.

[0032] It will be appreciated that the broad forms of the invention and their respective features can be used in conjunction, interchangeably and/or independently, and reference to separate broad forms is not intended to be limiting.

Brief Description of the Drawings

[0033] An example of the present invention will now be described with reference to the accompanying drawings, in which: -

[0034] Figure 1 is a schematic side view of an arm with an end effector utilised in an embodiment;

[0035] Figure 2 is a schematic side view detail of part of the arm shown in Figure 1;

[0036] Figure 3 is a schematic cross-section through part of the arm shown in Figure 1;

[0037] Figure 4 is a schematic side view of detail of part of a conveyer according to an embodiment;

[0038] Figure 5A is a perspective view of a turret used in the conveyer with a turret shuttle extended radially outward;

[0039] Figure 5B is a perspective view of the turret of Figure 5A with turret shuttle extending along the axial extent of the turret;

[0040] Figure 6 is a perspective view of a multi-bay carousel used in the conveyer,

[0041] Figures 7 to 14 are a sequence of side views showing detail of part of the conveyer in operation;

[0042] Figure 15 is a perspective view of an example of a transfer robot shown placing an object onto the multi-bay carousel; and,

[0043] Figure 16 is a side view of an automatic brick laying machine having a conveyer for transferring bricks to an end effector. Detailed Description of the Preferred Embodiments

[0044] The embodiment is a conveying system having a multi-bay carousel 11 for use in a supply line where piece parts are transferred from unloading and initial processing, to further processing in an additive manufacturing process. The particular application envisaged for the carousel 11 is in an automated brick laying machine. The carousel 11 is placed in a position between unloading and cutting and milling operations for bricks, and transport to an end effector 15 where the bricks are glued and laid.

[0045] An example of an automated brick laying robot machine 300 is shown in Figure 16. The brick laying machine has a base 310 in the form of a truck with a turntable in the form of a tower (or turret) 25 supported on a vertical yaw axis, and an articulated arm having a telescoping boom 17 supported on the tower 25 about a horizontal pitch axis about which the arm may be raised or lowered. The boom 17 has a telescoping stick, mounted on the end of the boom 17 about a horizontal pivot axis, and an end effector 15 in the form of an adhesive applying and brick laying head 43 mounted to the remote end of the stick. Bricks are stored in a storage area of the truck and a conveyer conveys the bricks from the truck 13 to the adhesive applying and brick laying head 43 via the carousel, turret and arm.

[0046] The bricks are transported inside a boom in the form of a folding and telescoping arm indicated generally at 17. The boom 17 has telescoping boom elements 19 and 21 that telescope with respect to each other in a controlled manner, powered by servo motors. The near end 23 of the boom element 19 is mounted to a turret 25 about a horizontal axis 27 allowing the boom 17 to be raised and lowered in a vertical plane.

[0047] At the remote end 29 of boom element 21, a telescoping stick assembly comprising telescoping stick elements 31, 33, and 35 is mounted about a horizontal axis 37. The telescoping stick elements 31, 33, and 35 can telescope with respect to each other in a controlled manner, powered by servo motors. Further details of an embodiment of the boom and end effector are shown in Figure 1. At the remote end 39 of stick element 35, mounted about a horizontal axis 41 for pivoting movement is an adhesive applying and brick laying head 43. The adhesive applying and brick laying head 43 has the end effector 15 attached thereto. The end effector 15 has a base 45, robotic arm 47 and gripper 49 for receiving gripping and placing bricks 13. The base 45 can rotate the robotic arm 47 about a horizontal axis 51 and the arm can both pivot about a horizontal axis 53 and slide along its axial length in a carriage located in the base 45, in order to effect fine positioning of the gripper 49. The adhesive applying and brick laying head 43 is rotated about its axis 41 under control of an actuator, controlled so that the base 45 axis 51 is maintained horizontally.

[0048] Telescoping boom element 19 has a track 55 extending therealong, along the bottom of the boom element 19. The track supports a shuttle 57 with gripper 59 to grip a brick 61. The shuttle 57 can traverse the length of the track 55 until it reaches boom element 21. Telescoping boom element 21 also has a track 63 extending therealong, the top of the boom element 21. The track 63 supports a shuttle 65 with gripper 67 to grip a brick 69. The shuttle 65 can traverse the entire length of the track 63 until it reaches stick element 31.

[0049] Telescoping stick element 31 has a track 71 extending therealong, along the top of the stick element 31. The track 71 supports a shuttle 73 with gripper 75 to grip a brick 77. The shuttle 73 can traverse the length of the track 71 until it reaches stick element 33. Telescoping stick element 33 has a track 79 extending therealong, along the bottom of the stick element 33. The track 79 supports a shuttle 81 with gripper 83 to grip a brick 85. The shuttle 81 can traverse the length of the track 79 until it reaches stick element 35. Telescoping stick element 35 has a track 87 extending therealong, along the top of the stick element 35. The track 87 supports a shuttle 89 with gripper 91 to grip a brick 93. The shuttle 89 can traverse the length of the track 87 until it reaches the adhesive applying and brick laying head 43.

[0050] The shuttles can move along the tracks within their respective boom or stick elements, to move bricks along the folding telescoping arm. Where the telescoping elements meet, the shuttles can meet with their grippers coincident, as shown in figure 2, allowing a brick to be passed from one shuttle to the next. In this manner the bricks are passed from shuttle to shuttle to move the object out along the folding and telescoping arm 17.

[0051] The turret 25 is mounted to a base 95, and is rotatable about a vertical axis 97 so that the folding and telescoping arm 17 may sweep radially about the base 95. [0052] The turret 25 has a shuttle 101 with a gripper 103 which grips a brick and is mounted on a vertically extending track 104, so that the object can be transported from where it is placed at the bottom of the turret 25, up the turret 25, to be presented to a gripper 105 mounted on a pivoting bracket 107 also about the horizontal axis 27. The pivoting gripper 105 can rotate about the horizontal axis 27 to align with the turret shuttle gripper 103, to receive the brick from the turret shuttle gripper 103, and rotate to align with the boom shuttle gripper 59, to transfer the brick from the turret 25 to the boom element 19.

[0053] As the turret 25 rotates relative to the base, the vertically extending track 104 with its turret shuttle 101 rotates with it. The carousel 11 is located extending around the bottom 113 of the turret 25, and is controllably rotatable around the turret 25, so that a brick can be placed on the carousel 11 by a transfer robot gripper 115 (as shown in Figure 15), and the carousel 11 can be rotated so that the brick is aligned with the turret shuttle track 104 to present the brick to the turret shuttle gripper 103. The gripper 103 on the turret shuttle 101 rotates about a transverse axis formed by a pivot hub 117 driven by a servo motor 119, so the gripper 103 can reach horizontally across the carousel 11, and swing upward to the vertical position (shown as 103') so it can present the brick to the pivoting gripper 105 after the turret shuttle has traversed the turret 25 along the vertically extending track 104. An exemplary example of a transfer robot 200 is shown in Figure 15 in which a robotic arm 210 with gripper 115 carrying a brick 230 extend over the carousel 11 and places the brick into one of the object bays.

[0054] Referring to figure 6, the carousel 11 is shown in greater detail. The carousel 11 has a ring frame 121 which rotates around the turret 25. The ring frame 121 has six object bays 123, 125, 127, 129, 131, and 133. Each object bay supports a gripper formed by jaws 135 and 137, carried on a bearing rod 139 and a lead screw 141. The jaws 135 and 137 have precision threads or lead nuts to match the threads on the lead screw 141. A motor 143 with toothed pulley drives a toothed belt 145 to drive a toothed pulley secured to the lead screw 141. Rotation of the motor 143 in one direction moves both jaws 135 and 137 away from each other, and rotation in the other direction moves the jaws 135 and 137 towards each other. A centre plane between the jaws 135 and 137 remains in a constant position as the jaws 135 and 137 move, so that any brick will be located centrally relative to the jaws 135 and 137 despite possible differing brick widths.

[0055] The base 95 supports a ring guide 147 mounted on a frame 148. The ring guide 147 supports a plurality of rollers that in turn support the ring frame 121 forming a slew bearing which is thus able to rotate about the vertical axis 97. The ring frame 121 is rotated about the vertical axis 97 by a servo motor and gearbox 153 that drives a pinion 155 engaged with a ring gear fixed to the underside of the ring fame 121. The servo motor and gearbox 153 is mounted to the frame 148. A cable chain 157 extends from the frame 148 and is confined by circular sheet metal cable chain guide 159 with circumferential wall 161 to contain the cable chain 157. The cable chain 157 extends to a cable duct 163 which supplies power and control signals to the motors 143 on the object bays 123, 125, 127, 129, 131, and 133. The cable chain guide 157 and cable duct 163 rotate with the ring frame 121.

[0056] The carousel 11 can rotate to present any of the object bays 123, 125, 127, 129, 131, and 133 to a position where the transfer robot gripper 115 can place a brick, and rotate the predetermined object bay 123, 125, 127, 129, 131, or 133 to a drop off position where the gripper 103 of the shuttle 101 on the turret 25 can rotate down to pick up the brick, ascend the turret, and rotate upward to align the brick vertically along the turret.

[0057] Referring to figures 5A and 5B, the vertically extending track 104 is formed by two parallel spaced linear bearing rails. The linear bearing rails respectively support four bearing cars which support the turret shuttle 101 which in turn supports the gripper 103. As can be seen in figure 5 a, the turret shuttle supports a servo motor 165 with toothed pinion which engages a toothed rack 167 to drive the turret shuttle 101 along the vertically extending track 104.

[0058] The grippers 103 are located on bearing cars 169 running along tracks 171, driven by a servo motor driving a drive belt 173 that drives a lead screw to open and close the grippers 103, to grip and release the brick.

[0059] Similarly, in the pivoting bracket 107, there is located a servo motor 175 driving a toothed belt 177 which drives a lead screw to move the jaws that make up the gripper 105. The grippers are also mounted on bearing cars for linear movement along tracks. The grippers 105 are referred to as pivoting grippers for brevity, on account of the pivoting bracket 107 on which they are mounted. The pivoting bracket 107 is rotated about the axis 27 by a servo motor 179 driving a toothed belt 181 which drives a hub 183 with internal reduction gearing.

[0060] A bracket 191 extends laterally outward from one side 193 of the turret 25 and another like bracket 195 extends laterally outward from the other side 197 of the turret. Bolts 199 on the brackets 191 and 195 are arranged with their axial extents coaxial with the vertical axis 97, and secure to the ring guide 147 of the carousel 11. Thus as the turret is rotated about the vertical axis 97, the carousel 11 rotates with it, but the carousel 11 may be independently rotated relative to the turret 25 by operation of servo motor and gearbox 153.

[0061] The turret 25 supports a lug 209 with a bore 213 having a horizontal axis 214, the bore receiving a fastener to connect an end of hydraulic ram (not shown) to control the pose of the boom element 19. The turret 25 supports clevis plates 210, 211 which have a bore 212 with horizontal axis 27, about which the near end 23 of the boom element 19 is attached for pivoting movement.

[0062] Referring to figures 4 and 7 to 14, a sequence of views illustrate the conveyance of bricks for constructing a building through the carousel 11, turret 25 into the near end 23 of the boom element 19. In figure 4, the transfer robot gripper 115 holds a brick and one at a time places such bricks horizontally in one of the object bays 123, 125, 127, 129, 131, and 133. In this case, transfer robot gripper 115 and brick is poised over object bay 131. The carousel 11 is rotated to present any one of the object bays 123, 125, 127, 129, 131, and 133 to the gripper 103 on the turret shuttle 101. Referring to figure 7, the carousel is rotated to present object bay 123 in a position where it can be accessed by the gripper 103 on the turret shuttle 101. Turret shuttle 101 descends down the turret 25 until its gripper 103 reaches a predetermined position in which it can grip the brick, as shown in figure 8. The gripper 103 grips the brick and the grippers 135 137 of object bay 123 release the brick.

[0063] The gripper 103 of the turret shuttle 101 is rotated about the pivot hub 117 in order to present the brick vertically as shown in figure 9. The turret shuttle 101 ascends the turret 25 until the brick reaches a predetermined position proximal to the gripper 105 of the pivoting bracket 107, as shown in figure 10. In this position, the gripper 105 grips the brick before the gripper 103 releases the brick. The pivoting bracket 107 rotates about the horizontal axis 27 as shown in figures 11 and 12, until the brick is aligned with the axial extent of the boom 19. While this has progressed, the shuttle 57 has moved on its track within the boom element 19 until its gripper 59 reaches a predetermined position where the gripper 59 grips the brick before the gripper 105 releases the brick, whereafter the shuttle moves the brick along the boom 19. Gripper 105 is rotated to a horizontal position about the horizontal axis 27, before pivoting bracket 107 rotates away from the boom 19, as shown in figures 13 and 14. The carousel may then rotate to present another object bay to the turret shuttle and the process repeats.

[0064] The object bays 123, 125, 127, 129, 131, and 133 of the carousel 11 function as a buffer which can be operated in two ways. Where the brick laying operation is running smoothly, the object bays may be fully stocked with bricks. In this manner where there is an operation performed on a brick, taking some time to perform, prior to it being placed in an object bay, such as a cutting operation or routing operation, or especially both a cutting and a routing operation, the brick laying may continue with stock already loaded onto the carousel, depleting that stock until the loading of the carousel is able to catch up. Where there has been a cutting operation, both the cut to length brick and the offcut can be stored in separate object bays, with the offcut being saved until such time as a brick of the length of the offcut is required.

[0065] The other mode of operation is where the placement of a brick by the adhesive applying and bricklaying head is potentially troublesome. This could be where the brick has been machined in a configuration that risks breakage as it is handled. In such a situation, the object bays are run empty, and any bricks that are enroute along the boom and stick, can be reversed out and back down the tower, before being stored in the object bays 123, 125, 127, 129, 131, and 133 of the carousel 11, while a replacement brick is machined and placed in one of the object bays 123, 125, 127, 129, 131, and 133 of the carousel 11, and is transferred as described to the boom and out to the brick laying and adhesive applying head. [0066] Thus the carousel allows storage of brick offcuts for later use, as well as providing a buffer to provide some surge capacity, allowing for different processes that take different times. The buffer may absorb stock from previous processes and provide stock immediately to the next process.

[0067] The carousel is also able to receive stock in a random order from a number of parallel previous processes and through selection of the object bays, the stock can be sequenced into a desired order for downstream processes.

[0068] Throughout this specification and claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers.

[0069] Persons skilled in the art will appreciate that numerous variations and modifications will become apparent. All such variations and modifications which become apparent to persons skilled in the art, should be considered to fall within the spirit and scope that the invention broadly appearing before described.