JP6748741 | Fastening tool |
WO1998013156A1 | 1998-04-02 |
DE102004011846A1 | 2004-09-23 |
CLAIMS A diagnostic system for a rivet delivery device, the rivet delivery device comprising a magazine configured to contain a supply of rivets, a separator configured to separate rivets from the magazine and a receiver to which rivets are delivered from the separator and from which the rivet is applicable to a work piece, and the rivet delivery device being arranged, under the control of a controller, to perform a separation action and a feeding action during riveting, where in the separation action the separator separates a rivet from the magazine and positions the rivet for commencement of the feeding action, and in the feeding action the rivet is fed from the separator to the receiver, and the diagnostic system comprising a diagnostic device being arranged to replace the controller in controlling the rivet delivery device during a diagnostic test, the diagnostic device having a processing means and a user interface means, the processing means being controllable via the user interface means to select and cause independent performance by the rivet delivery device of one of the actions and/or one or some sub-actions that make up the actions. A diagnostic system according to claim 1 wherein the diagnostic device is a handheld device. A diagnostic system according to claim 1 or claim 2 wherein the controller controls the rivet delivery device during riveting via one or more communication cables and the diagnostic device is arranged to be connected with the one or more communication cables removed from communication with the controller. A diagnostic system according to any preceding claim wherein the processing means is controllable via the user interface means to select and cause performance of both actions. A diagnostic system according to any preceding claim wherein a selectable and performable sub-action using the diagnostic device is activation of an actuator of the separator to drive a reciprocating magazine slide configured to carry a rivet out of the magazine, position it for delivery to the receiver and return ready to repeat the process once the rivet has been taken for delivery. 6. A diagnostic system according to any preceding claim wherein the magazine has a magazine tube, the magazine tube being configured to contain the supply of rivets. 7. A diagnostic system according to claim 6 wherein a selectable and performable sub-action using the diagnostic device is opening of a magazine air valve which allows delivery of a magazine air flow to the magazine tube, the air flow being sufficient to force any rivets in the magazine tube towards the separator regardless of magazine tube orientation. 8. A diagnostic system according to claim 6 or claim 7 wherein a selectable and performable sub-action using the diagnostic device is opening of a reverse air valve which allows delivery of a reverse air flow to the magazine tube, the reverse air flow being sufficient to temporarily displace any rivets in the magazine tube away from the separator. 9. A diagnostic system according to any preceding claim wherein the rivet delivery device comprises a feeding unit comprising a feed tube configured to carry rivets and where in the feeding action the rivet is fed from the separator to the receiver via the feed tube. 10. A diagnostic system according to claim 9 wherein a selectable and performable sub-action using the diagnostic device is opening of a feed tube air valve which allows delivery of blow air to the feed tube for driving any rivet present from the separator to the receiver. 1 1 . A diagnostic system according to claim 9 or claim 10 wherein the processing means is controllable via the user interface means to perform a speed test in which the separation and feeding actions are performed and the processing means displays on the diagnostic device an indicator dependent on the time it measures between a detected rivet loading action and receipt of a signal from a rivet arrival sensor indicating rivet arrival at a predetermined location within the feed tube. 12. A diagnostic system according to any preceding claim wherein the diagnostic device comprises one or more input sensor communication ports each arranged to be selectively connected to an output communication port of a sensor of the rivet delivery device by a respective sensor test cable. 13. A diagnostic system according to claim 12 when dependent through to claim 1 1 wherein the signal from the rivet arrival sensor sent during the speed test to the diagnostic device is sent via an output communication port of the rivet arrival sensor, a sensor test cable and an input communication sensor port of the diagnostic device. 14. A diagnostic system according to any preceding claim wherein the processing means is controllable via the user interface means to indicate whether a sensor signal indicative of a detected event is sent from a sensor of the rivet delivery device where an output communication port of the sensor and an input communication sensor port of the diagnostic device are connected by a sensor test cable and the rivet delivery device is placed in a condition whereby the sensor should send a signal indicative of the detected event. 15. A diagnostic system according to any preceding claim wherein the processing means is controllable via the user interface means to perform an actuator rear switch test, the actuator rear switch being arranged to output a signal when the reciprocating magazine slide has been driven to a position such that a rivet it is carrying is aligned for the feeding action to begin, and the test indicating whether a signal is output from the actuator rear switch when this position is reached. 16. A diagnostic system according to any preceding claim wherein the processing means is controllable via the user interface means to perform a magazine maximum fill sensor test, the magazine maximum fill sensor being arranged to output a signal when the magazine being loaded with rivets by a feeder has reached a predetermined fill level, and the test indicating whether a signal is output from the magazine maximum fill sensor when the predetermined fill level is reached. 17. A diagnostic system according to any preceding claim wherein two or more of the sub-actions are selectable for running concurrently. 18. A diagnostic system according to any preceding claim wherein the rivet delivery device comprises multiple magazines from which the separator may selectively collect rivets. 19. A method of using the diagnostic system of any of claims 1 to 18 wherein the controller indicates that there is no rivet in the receiver; comprising the steps of: i) connecting the diagnostic system to the rivet delivery device and using the user interface means to select performance of the separation action and the feeding action and observing for faults during performance of the actions; ii) where a fault is suspected but is unconfirmed, performing one or more further actions, sub-actions, combinations of actions and/or sub-actions and tests indicative of the presence of the suspected fault. 20. A method according to claim 19 comprising performing a communication cable test in which one, some or all of the communication cables are tested by selecting one or more actions, sub-actions, combinations of actions and/or sub- actions and tests for performance and observing for an unscheduled interruption in that or those actions, sub-actions, combinations of actions and/or sub-actions and tests when the communication cable under test is moved. 21 . A method according to claim 20 wherein the cable test is performed whilst the actuator of the separator is activated to drive the reciprocating magazine slide in automatic repeated reciprocation. 22. A method of controlling a rivet delivery device is provided, the rivet delivery device comprising a magazine configured to contain a supply of rivets, a separator configured to separate rivets from the magazine and a receiver to which rivets are delivered from the separator and from which the rivet is applicable to a workpiece, and the rivet delivery device being arranged, under the control of a controller, to perform a separation action and a feeding action during riveting, where in the separation action the separator separates a rivet from the magazine and positions the rivet for commencement of the feeding action, and in the feeding action the rivet is fed from the separator to the receiver, the method comprising: selecting and causing independent performance of one of the actions and/or one or some sub-actions that make up the actions. |
TECHNICAL FIELD
The present disclosure relates to diagnostics of a rivet delivery device and particularly, but not exclusively, to application of diagnostics in respect of rivet delivery devices on assembly lines. Aspects of the invention relate to a diagnostic system and to a method of using a diagnostic system, where the diagnostic system and the method of using a diagnostic system are the subjects of each the independent claims. BACKGROUND
Robotised riveting machines are used in many manufacturing processes, including for instance on automotive production lines. Typically a riveting delivery device or tool is manipulated by an articulated robot arm to various locations around a work piece, the riveting delivery device applying rivets at those locations. The movements of the robot arm to position the riveting delivery device as well as the application of rivets may be automated and/or pre-programmed in accordance with the particular manufacturing process.
The riveting delivery device may for instance comprise a magazine configured to contain a supply of rivets, a separator configured to separate rivets from the magazine, a feed tube and a receiver to which rivets are delivered from the separator via the feed tube and from which the rivet is applicable to the work piece.
The robot arm, riveting delivery device and at least part of the work piece may be surrounded by a guard structure known as a cell. The guard structure may help to protect operators, other personnel and equipment from inadvertently straying into a working area of the robot arm and/or riveting device, therefore protecting personnel and equipment. A control and monitoring station for the robot arm and/or riveting delivery device may be located outside of the cell. The control and monitoring station may have a controller allowing some control over the riveting process via one or more communication cables connected to the riveting delivery device.
The controller may also indicate at the control and monitoring station if there is a problem with the riveting process. The controller may for example indicate 'no rivet in receiver' where a rivet arrival sensor has not been triggered, despite the controller having instructed that a rivet should be sent to the receiver. The controller may allow selection and performance of a single complete rivet application action to assist with fault identification. Despite this facility correct fault diagnosis can be labour intensive and time consuming. Typically two operators are required, one to repeatedly run the single complete rivet application action from outside of the cell whilst another watches the riveting delivery device with a view to identifying the fault (which may be intermittent). Communication between the operators may be challenging, especially where the working environment is noisy. Further there may be many possible causes of a fault, e.g. air supply faults, solenoid and/or valve faults, sensor faults, communication cable faults, magazine faults, actuator faults, feed tube faults etc. Further many of these faults may be difficult to directly observe during the course of the single complete rivet application action (especially where the fault is intermittent). Consequently the diagnosis and repair process may take a significant time and may frequently result in correctly functioning components being replaced in a trial and error process.
It is an object of embodiments of the invention to at least mitigate one or more of the problems of the prior art. SUMMARY OF THE INVENTION
Aspects and embodiments of the invention provide a diagnostic system and a method of using a diagnostic system as claimed in the appended claims.
According to an aspect of the invention there is provided a diagnostic system for a rivet delivery device, the rivet delivery device comprising a magazine configured to contain a supply of rivets, a separator configured to separate rivets from the magazine and a receiver to which rivets are delivered from the separator and from which the rivet is applicable to a workpiece,
and the rivet delivery device being arranged, under the control of a controller, to perform a separation action and a feeding action during riveting, where in the separation action the separator separates a rivet from the magazine and positions the rivet for commencement of the feeding action, and in the feeding action the rivet is fed from the separator to the receiver,
the diagnostic device being controllable to cause independent performance by the rivet delivery device of one of the actions and/or one or some sub-actions that make up the actions.
According to another aspect of the invention there is provided a diagnostic system for a rivet delivery device, the rivet delivery device comprising a magazine configured to contain a supply of rivets, a separator configured to separate rivets from the magazine and a receiver to which rivets are delivered from the separator and from which the rivet is applicable to a workpiece, and the rivet delivery device being arranged, under the control of a controller, to perform a separation action and a feeding action during riveting, where in the separation action the separator separates a rivet from the magazine and positions the rivet for commencement of the feeding action, and in the feeding action the rivet is fed from the separator to the receiver,
and the diagnostic system comprising a diagnostic device being arranged to replace the controller in controlling the rivet delivery device during a diagnostic test,
the diagnostic device having a processing means and a user interface means, the processing means being controllable via the user interface means to select and cause independent performance by the rivet delivery device of one of the actions and/or one or some sub-actions that make up the actions.
The diagnostic device may therefore be advantageous in that it allows control of the rivet delivery device to achieve separate performance of one of the actions and/or one or some sub-actions falling short of full performance of both actions. This may allow greater control for diagnostic testing purposes and faster diagnosis of faults. Further the diagnostic device may provide increased flexibility in terms of allowing an operator to be located away from a control and monitoring station of the controller and yet still control the rivet delivery device. In some embodiments the processing means comprises a processor and a memory electrically coupled to the processor, the memory having instructions stored therein and the processor being configured to access the memory and execute the instructions stored therein such that it is operable to cause independent performance by the rivet delivery device of one of the actions and/or one or some sub-actions that make up the actions, the actions and/or sub-actions being selected by a user via the user interface means which comprises a user interface.
In some embodiments the diagnostic device is a handheld device. This may allow the diagnostic device to be more easily transported between different rivet delivery devices and further may be more convenient where it is desired to be in a particular location whilst performing diagnostic tests (e.g. within the perimeter of a protective cell surrounding the rivet delivery device).
In some embodiments the controller controls the rivet delivery device during riveting via one or more communication cables and the diagnostic device is arranged to be connected with the one or more communication cables removed from communication with the controller. As will be appreciated the communication cable or cables may be used to send signals from the diagnostic device to the rivet delivery device to cause performance of the actions and/or sub- actions. Further the communication cable or cables may be used to send signals from the rivet delivery device to the diagnostic device indicative of the condition of the diagnostic device and/or parts thereof. In particular it may be that one communication cable is used to send signals from the diagnostic device and one communication signal is used to receive signals at the diagnostic device.
In some embodiments the processing means is controllable via the user interface means to select and cause performance of both actions. In this way, as well as allowing selection and performance of only one action and/or one or some sub-actions, the diagnostic device may also allow performance of both actions. This may be advantageous where a user wishes to observe the result of an attempt to perform both actions.
In some embodiments a selectable and performable sub-action using the diagnostic device is activation of an actuator of the separator to drive a reciprocating magazine slide configured to carry a rivet out of the magazine, position it for delivery to the receiver and return ready to repeat the process once the rivet has been taken for delivery. Whilst this sub- action is performed a user may discern a problem with an air supply, a problem with a solenoid that opens a valve for delivery of air to produce or contribute to producing reciprocating motion, a problem with the actuator or magazine slide itself, or a problem with sensors which confirm that the magazine slide is in a forward position (with the rivet positioned for commencement of the feeding action) or a reverse position (ready to carry a rivet out of the magazine). In some embodiments the processing means is controllable via the user interface means to cause automatic repeated reciprocation of the magazine slide. This may mean that testing for an intermittent fault or suspected intermittent fault with the actuator, magazine slide and/or other associated components is more convenient. In some embodiments the magazine has a magazine tube, the magazine tube being configured to contain the supply of rivets.
In some embodiments a selectable and performable sub-action using the diagnostic device is opening of a magazine air valve which allows delivery of a magazine air flow to the magazine tube, the air flow being sufficient to force any rivets in the magazine tube towards the separator regardless of magazine tube orientation. In some embodiments a selectable and performable sub-action using the diagnostic device is opening of a reverse air valve which allows delivery of a reverse air flow to the magazine tube, the reverse air flow being sufficient to temporarily displace any rivets in the magazine tube away from the separator.
In some embodiments the rivet delivery device comprises a feeding unit comprising a feed tube configured to carry rivets and where in the feeding action the rivet is fed from the separator to the receiver via the feed tube. Such an arrangement may be referred to as a passive receiver arrangement, in contrast to an active receiver arrangement (also contemplated) where there is no such feed tube and the separator feeds rivets directly to the receiver during the feeding action. Where the rivet delivery device is a passive receiver arrangement, additional sub-actions may be selectable and performable and additional diagnoses made by comparison with those discussed previously which may be applicable to both passive and active receiver arrangements.
In some embodiments a selectable and performable sub-action using the diagnostic device is opening of a feed tube air valve which allows delivery of blow air to the feed tube for driving any rivet present from the separator to the receiver. Whilst this sub-action is performed a user may discern a problem with an air supply, a problem with a solenoid that opens the feed tube air valve, a problem with the feed tube air valve itself or a problem with the feed tube.
In some embodiments the rivet delivery device comprises a magazine stocker arranged to supply rivets to the magazine. The rivet delivery device may be arranged to perform a stocking action, in which rivets are supplied to the magazine using the magazine stocker. In some embodiments the rivet delivery device is arranged to perform the stocking action under the control of the controller, whereas in other embodiments the rivet delivery device is arranged to perform the stocking action under the control of a separate magazine stocker controller. The magazine stocker may supply rivets to the magazine as they are used or when the number of rivets in the magazine is depleted to a particular level or exhausted. The magazine stocker may comprise a stocker actuator arranged to adjust a stocker piston between a supply position whereby rivets are released into the magazine from the magazine stocker and a closed position whereby rivet release into the magazine from the magazine stocker is prevented.
In some embodiments a selectable and performable action using the diagnostic device is driving the stocker actuator to adjust the position of the stocker piston between its supply and closed positions. Whilst this action is performed a user may discern a problem with the stocker actuator or stocker piston, or a problem with sensors, which confirm that the stocker piston is respectively in the supply position and the closed position. One or both of such sensors may be provided.
In some embodiments the processing means is controllable via the user interface means to cause automatic repeated reciprocation of the stocker piston. This may mean that testing for an intermittent fault or suspected intermittent fault with the stocker actuator, stocker piston and/or other associated components is more convenient.
In some embodiments the processing means is controllable via the user interface means to perform a speed test in which the separation and feeding actions are performed and the processing means displays on the diagnostic device an indicator dependent on the time it measures between a detected rivet loading action and receipt of a signal from a rivet arrival sensor indicating rivet arrival at a predetermined location within the feed tube.
In some embodiments the detected rivet loading action comprises one of activation of the actuator of the separator and receipt of a signal from an actuator rear switch indicating that the magazine slide is positioned for rivet entry into the feed tube.
In some embodiments the diagnostic device comprises one or more input sensor communication ports each arranged to be selectively connected to an output communication port of a sensor of the rivet delivery device by a respective sensor test cable. In some embodiments the signal from the rivet arrival sensor sent during the speed test to the diagnostic device is sent via an output communication port of the rivet arrival sensor, a sensor test cable and an input communication sensor port of the diagnostic device.
In some embodiments the processing means is controllable via the user interface means to indicate whether a sensor signal indicative of a detected event is sent from a sensor of the rivet delivery device where an output communication port of the sensor and an input communication sensor port of the diagnostic device are connected by a sensor test cable and the rivet delivery device is placed in a condition whereby the sensor should send a signal indicative of the detected event.
In some embodiments the processing means is controllable via the user interface means to perform an actuator rear switch test, the actuator rear switch being arranged to output a signal when the reciprocating magazine slide has been driven to a position such that a rivet it is carrying is aligned for the feeding action to begin, and the test indicating whether a signal is output from the actuator rear switch when this position is reached. In some embodiments the processing means is controllable via the user interface means to perform a magazine maximum fill sensor test, the magazine maximum fill sensor being arranged to output a signal when the magazine being loaded with rivets by a feeder has reached a predetermined fill level, and the test indicating whether a signal is output from the magazine maximum fill sensor when the predetermined fill level is reached.
In some embodiments two or more of the sub-actions are selectable for running concurrently.
In some embodiments, multiple diagnostic checks are selectable for automatic performance in a routine and the processing means analyses the results of the diagnostic checks to determine a possible and/or suspected fault or faults. The result(s) of this analysis may then be displayed on the display screen.
In some embodiments the rivet delivery device comprises multiple magazines from which the separator may selectively collect rivets. There may for instance be two magazines, which may be identified as master and slave. The magazines may contain different rivet types (e.g. sizes). Each magazine may have one, some or all of an associated magazine air valve, reverse air valve and magazine maximum fill sensor as previously described. Alternatively one or more of these components may be shared between the magazines. As will be appreciated all previously described tests and actions may also be selectable and/or performable for these components independently of those for other similar components associated with a different magazine. Further similar actions and sub-actions selectable and performable that involve one magazine may be equally and independently selectable and performable for any other magazine present.
In some embodiments the processing means determines the number of rivets that have reached the receiver. This number may be indicated on the display screen. Further the processing means may determine the number of rivets received from the master magazine and the number from the slave magazine. In this case the number from each may be indicated on the display screen. The determination may be made for the number of rivets received during a given diagnostic exercise (e.g. since the diagnostic device was switched on, connected to the rivet delivery device and/or the receipt of a user input indicating the start of a diagnostic exercise). Determination of the number of rivets reaching the receiver may be made in accordance with signals from the rivet arrival sensor.
As will be appreciated one some or all, actions, sub-actions, combinations of actions and/or sub-actions, tests and similar events indicated to be activatable via the diagnostic device may also be deactivatable via the diagnostic device (e.g. via the user interface means).
In some embodiments the diagnostic device is isolated from control of a spindle of the rivet device. It may be for instance that the diagnostic device has no control functionality which allows adjustment of the spindle. This may prevent injury or accident that might otherwise occur were the diagnostic device used to control the spindle with an operative located within a physical barrier surrounding parts of the rivet delivery device including the spindle.
According to a further aspect of the invention there is provided a method of using the diagnostic system of the previous aspect, where the controller indicates that there is no rivet in the receiver; comprising the steps of:
i) Connecting the diagnostic system to the rivet delivery device and using the user interface means to select performance of the separation action and the feeding action and observing for faults during performance of the actions; ii) Where a fault is suspected but is unconfirmed, performing one or more further actions, sub-actions, combinations of actions and/or sub-actions and tests indicative of the presence of the suspected fault.
In some embodiments step ii) comprises performing one or more of the following in accordance with the nature of the suspected fault:
a) Activation of the actuator of the separator;
b) Opening of the magazine air valve;
c) Opening of the reverse air valve;
d) Opening of the feed tube air valve;
e) The speed test;
f) The actuator rear switch test;
g) The magazine maximum fill test;
h) The rivet arrival sensor test;
i) A communication cable test.
In some embodiments at least one of the rivet arrival sensor test and the speed test is performed if a rivet is observed to arrive at the receiver in step i). In some embodiments where a speed test is performed, at least one further speed test is performed and the results compared to establish whether or not they are substantially consistent. Inconsistent results may indicate that the magazine slide is operating at different speeds on different cycles, and may need to be replaced.
In some embodiments the method further comprises performing a communication cable test in which one, some or all of the communication cables are tested by selecting one or more actions, sub-actions, combinations of actions and/or sub-actions and tests for performance and observing for an unscheduled interruption in that or those actions, sub-actions, combinations of actions and/or sub-actions and tests when the communication cable under test is moved.
In some embodiments the cable test is performed whilst the actuator of the separator is activated to drive the reciprocating magazine slide in automatic repeated reciprocation.
In some embodiments the method comprises performing a sensor test by connecting an input sensor communication port of the diagnostic device with an output communication port of a sensor to be tested via a sensor test cable, placing the rivet delivery device in a condition whereby the sensor should send a signal indicative of a detected event and checking the diagnostic device for confirmation that such a resulting signal has been sent.
In some embodiments, where a fault is observed during step (i) or is confirmed during step (ii), the method comprises conducting corresponding repair and/or replacement.
In some embodiments the method comprises optionally repeating step (i) where no fault is observed.
According to a still further aspect of the invention a method of controlling a rivet delivery device is provided, the rivet delivery device comprising a magazine configured to contain a supply of rivets, a separator configured to separate rivets from the magazine and a receiver to which rivets are delivered from the separator and from which the rivet is applicable to a work piece,
and the rivet delivery device being arranged, under the control of a controller, to perform a separation action and a feeding action during riveting, where in the separation action the separator separates a rivet from the magazine and positions the rivet for commencement of the feeding action, and in the feeding action the rivet is fed from the separator to the receiver, the method comprising:
selecting and causing independent performance of one of the actions and/or one or some sub-actions that make up the actions.
In some embodiments a selected and performed sub-action is activation of an actuator of the separator to drive a reciprocating magazine slide configured to carry a rivet out of the magazine, position it for delivery to the receiver and return ready to repeat the process once the rivet has been taken for delivery.
In some embodiments the method comprises selecting and performing automatic repeated reciprocation of the magazine slide.
In some embodiments the magazine has a magazine tube, the magazine tube being configured to contain the supply of rivets.
In some embodiments a selected and performed sub-action is opening of a magazine air valve which allows delivery of a magazine air flow to the magazine tube, the air flow being sufficient to force any rivets in the magazine tube towards the separator regardless of magazine tube orientation.
In some embodiments a selected and performed sub-action is opening of a reverse air valve which allows delivery of a reverse air flow to the magazine tube, the reverse air flow being sufficient to temporarily displace any rivets in the magazine tube away from the separator.
In some embodiments the rivet delivery device comprises a feeding unit comprising a feed tube configured to carry rivets and where in the feeding action the rivet is fed from the separator to the receiver via the feed tube. In some embodiments a selected and performed sub-action is opening of a feed tube air valve which allows delivery of blow air to the feed tube for driving any rivet present from the separator to the receiver.
In some embodiments a selected and performed action is driving the stocker actuator to adjust the position of the stocker piston between its supply and closed positions. In some embodiments the method comprises selecting and performing automatic repeated reciprocation of the stocker piston.
In some embodiments the method comprises performing a speed test in which the separation and feeding actions are performed and an indicator dependent on a time measured between a detected rivet loading action and receipt of a signal from a rivet arrival sensor indicating rivet arrival at a predetermined location within the feed tube is displayed.
In some embodiments the method comprises performing an actuator rear switch test, the actuator rear switch being arranged to output a signal when the reciprocating magazine slide has been driven to a position such that a rivet it is carrying is aligned for the feeding action to begin, and the test indicating whether a signal is output from the actuator rear switch when this position is reached. In some embodiments the method comprises performing a magazine maximum fill sensor test, the magazine maximum fill sensor being arranged to output a signal when the magazine being loaded with rivets by a feeder has reached a predetermined fill level, and the test indicating whether a signal is output from the magazine maximum fill sensor when the predetermined fill level is reached.
In some embodiments the method comprises selecting and performing concurrent running of two or more of the sub-actions.
In some embodiments the method comprises selecting and performing multiple diagnostic checks in a routine and analysing the results of the diagnostic checks to determine a possible and/or suspected fault or faults.
In some embodiments the method comprises determining the number of rivets that have reached the receiver. This number may be indicated. Further the method may comprise determining the number of rivets received from the master magazine and the number from the slave magazine. In this case the number from each may be indicated.
In some embodiments the method comprises deactivating one, some or all, actions, sub- actions, combinations of actions and/or sub-actions, tests and similar events where they have been activated as part of the method. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.
BRIEF DESCRIPTION OF THE DRAWINGS
One or more embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a perspective view of a rivet delivery device and a diagnostic system according to an embodiment of the invention;
Figure 2 shows a schematic view of a rivet delivery device; Figure 3 shows a schematic view of parts of a rivet delivery device and a diagnostic system according to an embodiment of the invention;
Figure 4 shows a schematic view of parts of a rivet delivery device and a diagnostic system according to an embodiment of the invention;
Figure 5 shows a user interface option selection map for a diagnostic system according to an embodiment of the invention; and
Figure 6 shows a diagnostic sequence using the diagnostic system in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
Referring first to Figures 1 to 4, an embodiment of a rivet delivery device 10 and diagnostic system 12 are described. The rivet delivery device 10 has a number of broad components: a feeder 14, a feeding unit 16 a feed tube 18, a spindle (or riveting tool) 20, a digital data converter 22 and a controller 24. The feeder 14 is arranged to supply, under the control of the controller 24, rivets to the feeding unit 16. In this case the feeding unit 16 has two magazines, master 26 and slave 28, each configured to contain a supply of rivets. The feeding unit 16 supplies a supply of smaller rivets to the master magazine 26 and supply of larger rivets to the slave magazine 28. Where the relevant magazine 26, 28 reaches a predetermined fill level during filling by the feeder 14, a magazine maximum fill sensor 30 associated with the relevant magazine 26, 28 outputs a signal to the controller 24. The signal is used by the controller to end filling of the relevant magazine 26, 28 by the feeder 14.
In each magazine 26, 28 the rivets are stored in a respective magazine tube (not shown). The magazine tubes share a magazine air valve 32 and each has a respective reverse air valve 34, 36. The magazine air valve 32 is actuatable under the control of the controller 24 to selectively deliver a magazine air flow to the both magazine tubes. The magazine air flow is in a direction and of sufficient strength to force any rivets towards an end of the respective magazine tube from which they can be taken by a separator 38 regardless of magazine tube orientation. Thus even where the feeding unit 16 (and therefore the magazine tubes) is tilted or inverted during riveting, rivets are forced towards and presented to the separator 38. The reverse air valves 34, 36 are actuatable under the control of the controller 24 to selectively deliver a reverse air flow to their respective magazine tubes. Each reverse air flow is in a direction and of sufficient strength to temporarily displace any rivets in the magazine tube away from the separator 38. Thus where there is a failure to deliver a rivet from a particular magazine 26, 28 the controller 24 can send a signal to open and close the relevant reverse air valve 34, 36. This will shuffle the rivets in the vicinity of the separator 38, whereupon they may fall back to the separator 38 in a distribution that allows successful rivet collection by the separator 38.
The separator 38 is configured to separate rivets from the magazines 26, 28 under the control of the controller 24. The separation occurs sequentially i.e. one rivet at a time. The origin of each rivet (i.e. master 26 or slave 28 magazine) separated is selectable by the controller in accordance with the rivet size required next. The separator 38 comprises an actuator (in this case a cylinder) corresponding to each magazine 26, 28. A master cylinder 40 corresponds to the master magazine 26 and a slave cylinder 42 corresponds to the slave magazine 28. Associated with each cylinder 40, 42 is a magazine slide configured to reciprocate in its respective cylinder 40, 42, a master magazine slide (not shown) associated with the master cylinder 40 and a slave magazine slide (not shown) corresponding to the slave cylinder. The reciprocation of each magazine slide is pneumatically driven under the control of the controller 24. An actuator rear switch (in this case a master cylinder rear switch 44) is arranged to send a signal to the controller indicating that the master magazine slide is in position for a feeding action to begin for a rivet collected by the master magazine slide from the master magazine 26. The controller 24 uses this signal to prompt the delivery of an air flow to drive the master magazine slide back to the position for collecting a rivet. Thereafter the controller 24 delivers an air flow to drive the master magazine slide forwards again carrying another rivet. This process may be continued for as long as rivet delivery is instructed by the controller 24. As will be appreciated a similar process occurs with respect to the slave magazine slide in accordance with respective signals from a slave actuator rear switch (in this case a slave cylinder rear switch 46).
Once the separation action described above (i.e. the separator 38 separates a rivet from a magazine 26, 28 and positions the rivet for commencement of the feeding action) is complete, a feeding action is commenced. In the feeding action, the rivet is fed from the relevant magazine slide to a receiver 48. The receiver 48 is located at a delivery end 50 of the spindle 20. From the receiver 48 a rivet is applicable to a workpiece. The receiver 48 is connected to the separator 38 (and specifically whichever magazine slide is delivering a rivet) by the feed tube 18. The feed tube 18 is configured to carry rivets from the relevant magazine slide to the receiver 48 using blow air to drive the rivet from the magazine slide to the receiver 48. Blow air is selectively deliverable to the feed tube 18 via the opening of a feed tube air valve (not shown) under the control of the controller 24. The controller opens the feed tube air valve when there is a rivet to be delivered to the receiver 48 i.e. when a signal is received from the relevant cylinder rear switch. A rivet arrival sensor 52 (in this case a proximity switch) provided on the feed tube 18 adjacent the receiver 48, detects whether a rivet has been delivered to the receiver 48. When a rivet is detected by the rivet arrival sensor 52 it sends a signal to the controller 24 indicating that a rivet is in the receiver 48.
Communication between the controller 24 and the various valves and sensors discussed occurs via communication cables. The communication cables include an output communication cable 54 for carrying signals sent from the controller 24 and an input communication cable 56 for carrying signals sent to the controller 24. The output 54 and input 56 communication cables are plugged into the digital data converter 22 at one end and the receiver unit 16 at the other. A general communication cable 58 connects the controller 24 to the digital data converter 22 for carrying all signals between the two. The rivet delivery 10 comprises two zones demarcated by a physical barrier 60. The physical barrier 60 separates the feeding unit 16, feed tube 18 and spindle 20 from the controller 24. The barrier 60 may therefore help to protect operatives outside of the physical barrier 60 (for instance operating a control and monitoring station of the controller 24) from moving parts of the rivet delivery device. Similarly the barrier 60 may help to protect the moving parts of the rivet delivery system from 10 from external interference, e.g. unintended collisions.
The rivet delivery device 10 described above may from time to time fail in accordance with one or more of several known failure mechanisms. The existence of a failure may become apparent to an operator of the rivet delivery device 10 where the controller reports that no rivet has been detected in the receiver 38, despite its instruction to perform the separation and feeding actions.
The controller 24 has very limited diagnostic capability to determine the exact nature of the failure and therefore the remedial repair and/or replacement required. Further the controller has no facility to allow separate performance of the separation and feeding actions, nor indeed separate performance of sub-actions that make up those separation and feeding actions. The physical separation in distance and provided by the physical barrier 60 also mean that an operative cannot operate the control and monitoring station of the controller 24 at the same time as being inside the physical barrier and observing the rivet delivery device 10 with a view to identifying the fault. Consequently fault diagnosis typically requires two operatives, one to operate the control and monitoring station of the controller 24 from outside the barrier 60 and one to observe the parts of the rivet delivery device 10 inside of the barrier 60. Communication between these operatives is typically challenging where the rivet delivery device 10 is located in a noisy production environment. Further the controller 24 can only be used to instruct performance of a complete rivet separation and feeding action. Thus the operative inside of the barrier 60 instructs as best he can the operative operating the control and monitoring station of the controller 24 to initiate the rivet separation and feeding actions as often as necessary until the fault is observed. Frequently the fault cannot be observed or is difficult to see, exacerbated because the controller 24 does not allow for particular actions and sub-actions to be performed, which would otherwise allow the observing operative to better focus attention on a suspect component. Consequently time consuming trial and error replacement of components is often conducted, leading in many cases to non-faulty components being replaced. Further instances of a fault apparently having been diagnosed and corrected, but in-fact not having been resolved and resurfacing may be relatively high.
A handheld diagnostic device 62 may however be used with a view to mitigating the problems described. The diagnostic device 62 is arranged to replace the controller 24 during a diagnostic test. The diagnostic device 62 has a processing means, in this case a processor (not shown) and a memory (not shown), a user interface means, in this case a user interface 64 and a display screen 66. The processor is controllable via the user interface 64 to instruct performance and cessation of rivet delivery device 10 actions and/or sub-actions and/or other tests (as discussed further below with reference to Figure 5). The display screen 66 is used by the processor to display selectable options, prompts and information concerning the diagnostic test. The processor calls programs and information stored in the memory in order to perform its various functions. The diagnostic device 62 communicates in part with the rivet delivery device 10 via the output communication cable 54 and the input communication cable 56, which for a diagnostic test are unplugged from the digital data converter 22 (and therefore the controller 24) and plugged into corresponding communication cable ports 68 of the diagnostic device 62. Further communication may be provided via one or more sensor test cables 69 one or both of which can be connected between a respective input sensor communication port 70 of the diagnostic device 62 and an output communication port of one of the sensors/switches of the rivet delivery device 10.
A diagnostic test performed with the diagnostic device 62 can be performed by a single operative, who can pass to the inside of the barrier 60 with the diagnostic device and make the necessary communication disconnections from the controller 24 and connections with the diagnostic device 62. Thereafter the operative can both operate the diagnostic device 62 and observe the parts of the rivet delivery device 10 located within the barrier 60 with a view to finding a fault or faults.
In conducting a diagnostic test the diagnostic device 62 allows the user to select between a number of options via the display screen 66 discussed further below with reference to Figure 5. As will be appreciated the nature of the user interface 64 and manner in which options are presented to a user may be different in other embodiments. By way of example, information may be presented across multiple display screens and/or through use of alternative interfaces (e.g. lights or auditory indicators). Further the information presented may be altered, e.g. some information/functionalities may be omitted and/or additional information/functionalities may be provided. By way of example, in some embodiments a graphic animation could be provided to indicate the current fill level of a magazine.
Upon activation, the display screen 66 shows a start-up window 72 for a time limited duration before displaying a main window 74. The main window 74 indicates that the device is ready to receive a test selection. The user may then select a test using the user interface 64 and the test selected is shown in the display screen 66. Figure 5 shows the various test options selectable from the main window 74. A first test (corresponding to user interface selection of F1 ) causes attempted separation and feeding actions (i.e. both actions) to be performed for a rivet in the master magazine 26 by the rivet delivery device 10. This prompts display of a 'rivet to receiver master side' window 76. A second test (corresponding to user interface selection of F2) causes attempted separation and feeding actions (i.e. both actions) to be performed for a rivet in the slave magazine 28 by the rivet delivery device 10. This prompts display of a 'rivet to receiver slave side' window 78. A third test (corresponding to user interface selection of F3) causes attempted separation and feeding actions (i.e. both actions) to be performed for a rivet in a magazine of an active receiver rivet delivery device. This prompts display of a 'rivet to receiver (active receiver)' window 80. An active receiver is a rivet delivery device where the separator and receiver are combined into a single component and there is no feed tube in the sense of a passive receiver rivet delivery device as described with reference to Figures 1 to 4. This test may only be usefully selected where the rivet delivery device is of the active receiver type.
A fourth test (corresponding to user interface selection of F4) causes attempted activation of the master cylinder 40 of the separator 38 to drive its magazine slide from a position where it is configured to carry a rivet out of the master magazine 26, to a position for delivery of the rivet to the receiver 48 and return ready to repeat the process once the rivet has been taken for delivery. This prompts display of a 'master cylinder active' window 82.
A fifth test (corresponding to user interface selection of F5) causes attempted activation of the slave cylinder 42 of the separator 38 to drive its magazine slide from a position where it is configured to carry a rivet out of the slave magazine 28, to a position for delivery of the rivet to the receiver 48 and return ready to repeat the process once the rivet has been taken for delivery. This prompts display of a 'slave cylinder active' window 84.
A sixth test (corresponding to user interface selection of F6) causes attempted activation of magazine air to both the master and slave magazine tubes via opening of the magazine air valve 32. This prompts display of a 'magazine air active' window 86.
A seventh test (corresponding to user interface selection of F7) causes attempted delivery of a reverse air flow to the master magazine tube via opening the master reverse air valve 34. This prompts display of a 'Reverse air active master side' window 88.
An eighth test (corresponding to user interface selection of F8) causes attempted delivery of a reverse air flow to the slave magazine tube via opening the slave reverse air valve 36. This prompts display of a 'Reverse air active slave side' window 90.
A ninth test (corresponding to user interface selection of F9) causes attempted delivery of blow air to the feed tube 18 via opening of the feed tube air valve. This prompts display of a 'spring air active' window 92. Once one of the tests described has been initiated via a user interface selection of any of F1 -F9, the same selection on the user interface 64 will result in deactivation of the relevant test and a return to the main window 74 on the display screen 66. Only one test is selectable at a time using the F1 -F9 user interface selections from the main window 74. Where however F0 is selected from the main window 74 on the user interface 64 (prompting display of a 'test solenoids active' window 93), further selections F1 -F9 may be made and multiple tests conducted at once (e.g. two or more tests may be selected to run concurrently). Where F0 is selected, subsequent selection of F4-F9 correspond to the similar tests described above accessible from the main window 74. Tests F1 -F3 accessible from the main window 74 are replaced with alternative test options when F0 is first selected from the main window 74. Specifically F1 and F2 selections respectively attempt activation of the master and slave cylinder for automatic repeated reciprocation (rather than performing a single forward/back cycle). Selection of F3 having first selected F0 from the main window 74 results in the repeated reciprocating test of the cylinder for an active receiver rivet delivery device. Once one of the tests described has been initiated via a user interface selection of any of F1 -F9 having first selected F0, the same selection on the user interface 64 will result in deactivation of the relevant test. Selecting F0 again returns the display screen 66 to the main window 74. A speed test (corresponding to user interface selection of F * ) allows attempted performance of separation and feeding actions (i.e. both actions) to be performed for a rivet in the master magazine 26 (by subsequently selecting F1 ) or a rivet in the slave magazine 28 (by subsequently selecting F2) by the rivet delivery device 10. Once selected the speed test prompts display of a 'speed test active' window 94. Once the speed test is completed the processor displays in the display screen 66 the time it measures between a detected rivet loading action and receipt of a signal from the rivet arrival sensor 52.
The speed test requires that a sensor test cable 69 is connected between an input sensor communication port 70 of the diagnostic device 62 and an output communication port 96 of the rivet arrival sensor 52. In this way a signal sent from the rivet arrival sensor 52 can be sent to the processor. Optionally an additional sensor test cable 69 can be connected between another input communication port 70 of the diagnostic device 62 and an output communication port 96 of the cylinder rear switch. Once the sensor test cable 69 or cables 69 to be used are connected, a user can indicate readiness to perform the speed test using the user interface (in this case by selecting F0). Where only one sensor test cable 69 is used, the detected rivet loading action is taken to be activation of the relevant cylinder 26, 28 of the separator 38. Where however two sensor test cables 69 are used, the detected rivet loading action is taken to be receipt of a signal from the cylinder rear switch indicating that the magazine slide is positioned for rivet entry into the feed tube 18. Use of the latter approach may give improved accuracy.
The speed test may be repeated in order that the times measured between the rivet loading action and receipt of the signal from the rivet arrival sensor 52 can be compared. Where these times are other than substantially equal, the test may be considered to indicate that the relevant magazine slide is faulty and should be replaced.
Selecting F * again returns the display screen 66 to the main window 74. Finally a sensor test (corresponding to user interface selection of F# which prompts display of a 'Test sensors' window 95) allows testing of a sensor/switch of the rivet delivery device connected to the diagnostic device via one of the sensor test cables 69 in a similar manner as described with respect to the speed test. Specifically the test is such that the display screen 66 will indicate whether a sensor signal indicative of a detected event is sent from a connected sensor of the rivet delivery device 10, where the rivet delivery device is placed in a condition whereby the sensor should send a signal indicative of the detected event. If no such signal is then received it may indicate that the sensor/switch is faulty. Sensors/switches that may be tested are the cylinder rear switch and the magazine maximum fill sensor test.
Selecting F# again returns the display screen 66 to the main window 74.
The tests discussed above may be used independently or in combination to test for a wide array of possible faults. These include faults with a particular sensor, switch, valve, valve solenoid, air supply, cable, magazine, magazine tube, cylinder, magazine slide or with the feed tube or receiver. The operator may intelligently deploy the tests systematically and/or based on experience of evidence indicating a particular suspected fault.
Additionally the processing means of the diagnostic device may provide an option for automatic performance of multiple diagnostic checks (a sub-set of the possible checks or all checks) in a routine and analyse the results to determine a possible and/or suspected fault or faults. By way of example, the output from one or more of the sensors, the output from which may predictably conform to nominal outputs where the rivet delivery device is performing nominally, may be monitored for nominal and/or non-nominal outputs, and the results used to predict a fault and/or the nature of a fault. It may be for instance that in a nominally operating rivet delivery device, the sensors are expected to give particular outputs at particular times within a riveting cycle. A failure to do so may be indicative of a fault with a corresponding part of the rivet delivery device. The result(s) of the analysis may be displayed on the display screen.
An embodiment of a diagnostic process generally shown at 100 is now described with reference to Figure 6. Nonetheless, as will be appreciated, different types, combinations and/or order of tests may well be performed in other cases.
In the example given the diagnostic process is performed by an operative following an indication on the control and monitoring station of the controller 24 that no rivet has been detected at the receiver 48, despite the controller 24 instructed that the separation and feeding actions should be performed for a rivet in the master magazine 26.
In a first connection step 102 an operator connects the diagnostic device to the rivet delivery device via the output communication cable 54 and the input communication cable 56.
In an explorative step 104 the operative selects performance of both the separation and feeding actions on the master side and observes for a fault. On this occasion however a rivet from the master magazine 26 is successfully delivered to the receiver 48 and the operative observes no fault, so the operative performs a repetition step 106 where he again selects performance of both the separation and feeding actions on the master side and observes for a fault. Following the repetition step 106 no rivet is delivered to the receiver 48. This indicates that the fault is probably intermittent and that it is unlikely to be caused by a faulty rivet arrival sensor 52.
Based on experience the operative suspects an intermittent fault with the feed tube air valve and so selects performance of automatic repeated automatic cycling of the feed tube air valve between open and closed. This sub-action test is performed in a feed tube air valve test step 108. The operative observes normal performance of the feed tube air valve throughout the test and so deactivates the automatic cycling in a feed tube air valve test end step 1 10. The operative then decides to perform a cable check and so in step 1 12 he selects performance of repeated automatic reciprocation of the master magazine slide by correspondingly activating the master cylinder. Whilst the master magazine slide is reciprocating the operative moves each of the output communication cable 54 and the input communication cable 56 in a cable moving step 1 14. When moving the communication cable 56 the operative observes intermittent interruptions in the reciprocating of the magazine slide. The operative therefore concludes that the input communication cable 56 is faulty. The operative deactivates the automatic reciprocation in a cable test end step 1 16 and replaces the input communication cable 56 in a cable replacement step 1 18. Finally the output communication cable 54 and the input communication cable 56 are reconnected for communication with the controller 24, in a controller reconnection step 120.
All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. The claims should not be construed to cover merely the foregoing embodiments, but also any embodiments which fall within the scope of the claims.
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