ROBOTIC VEHICLE TIRE AND WHEEL RIM ASSEMBLY

APPARATUS AND METHOD CROSS REFERENCE TO RELATED APPLICATION

|000l 1 The present application claims priority of U.S. provisional application Ser. No.

60/858,191, filed November 10, 2006, by Yves Desmet, Bart Nys, Ward Van De Walle, and Hannes Van Holm for ROBOTIC VEHICLE TIRE AND WHEEL RIM ASSEMBLY APPARATUS AND METHOD, which is hereby incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

|0002| This invention relates to the automated assembly of vehicle tires to wheel rims and, more particularly, to the automated assembly of vehicle tires to wheel rims using multi-axis robots for performing the various assembly functions.

BACKGROUND OF THE INVENTION

100031 In the modern manufacture of vehicles, it is commonplace to supply assembled wheels and tires of the specific size and design required to the assembly line for the vehicle being manufactured. Typically, the tires are assembled to wheels, inflated and balanced at a location remote from the assembly line. Thus, it is necessary to supply the assembled tires and wheels at a rate required for vehicle assembly at the precise time they are needed at the vehicle assembly line. As world competition in vehicle manufacture increases, the type and number of vehicle models specifying a wide range of tire sizes and designs is steadily increasing. Consequently, the provision of properly assembled and sized tire and wheel assemblies to supply the increasing number of vehicle types being manufactured is a significant challenge.

|0004| The assembly of tires to wheels in an automated fashion has become well known. In many prior wheel and tire assembly systems, a single type of tire is brought together with a corresponding wheel rim and assembled to produce a tire and wheel assembly of a specified size and design at the end of the assembly process. However, when more than one assembly line must be supplied, or a tire and wheel assembly manufacturer wishes to supply multiple vehicle assembly plants from a single location, it has been necessary to provide a large number of dedicated tire and wheel assembly systems each supplying one type of tire and wheel assembly for a specified period. The change between types of wheels and tires for different vehicles or for different manufacturers has either required significant capital investment for

larger numbers of dedicated assembly systems or has demanded significant time thereby detracting from vehicle manufacturing output. Even in certain prior systems that are able to assemble different or intermixed rim and tire styles, greater flexibility in handling a wider variety of different rim and tire sizes and styles is needed to accommodate vehicle manufacturing. Therefore, the need for greater flexibility in the manufacture of varying types of tire and wheel assemblies for the supply to a single manufacturer for varying types of vehicles or to multiple manufacturers from a single tire and wheel assembly location is now increasingly important.

100051 In addition, prior processing times for manufacturing a completed wheel and tire assembly have been lengthy. Relatively slow machines for lubricating the beads of tires or tire bead receiving areas of a wheel rim have increased the overall processing time for tire and wheel assembly. Similarly, the processing time for the manufacture of a completed tire and wheel assembly is lengthy due to the required time for supplying the desired tires and wheel rims, supporting the wheel rim while aligning the tire therewith, and engaging the tire with a mounting tool to pass the tire beads over the bead receiving rim flanges, following by inflation and balancing. A reduction in processing time for and/or consolidation of manufacturing steps is desired to increase the efficiency of the tire/wheel rim assembly process.

10006] Further, although it is known to premark and prebalance tires and rims for assembly in a desired orientation to reduce balance and uniformity problems in the resulting assembly, it was necessary to use a separate tire and wheel rim alignment machine prior to final assembly. The use of such extra processing steps therefore added to overall processing time for producing the completed tire and wheel rim assembly.

|0007| Accordingly, it is desired to provide a flexible tire and wheel rim assembly apparatus and process capable of assembling a wide variety of tire and rim combinations for various types of vehicles with reduced processing time and high reliability, accompanied by alignment of tire and wheel based on predetermined markings, without time consuming additional assembly steps.

SUMMARY OF THE INVENTION

|0008| Accordingly, the present invention provides an apparatus and method for assembling a vehicle tire to a wheel rim using robotic assembly techniques adapted to reduce cycle time in various of the processing steps, to provide flexibility for assembling various sizes and types of tires with various sizes and types of rims for varying vehicle models and makes, and

to provide the ability to align the tire and wheel rim with preset markings as part of the assembly process without additional time consuming alignment steps.

100091 In one aspect of the invention, a method for assembling a vehicle tire to a wheel rim comprises the steps of providing a robot, selecting one of a tire and wheel rim with the robot when the tire and wheel rim are supported adjacent the robot, moving the selected one of the tire and wheel rim to a lubrication area with the robot and applying a lubrication solution to one of the bead area of the selected tire or the tire bead engaging area of the selected wheel rim, and moving the selected one of the lubricated tire or wheel rim to a mounting assembly with the robot. The method further involves selecting the other of a tire and wheel rim with a selected robot selected from either the previously noted robot and another robot, moving the other of the selected tire and wheel rim to a lubrication area with the selected robot and applying a lubrication solution on one of the bead area of the other selected tire or the tire bead engaging area of the other selected wheel rim, and moving the other of the selected lubricated tire or wheel rim to the mounting assembly with the selected robot and mounting the tire on the wheel rim to form a tire/wheel rim assembly.

|OO1O| In another aspect of the invention, a robotic vehicle tire and wheel rim assembly apparatus comprises a multi-axis robot having an end effector configured for selecting at least one of either a tire and a wheel rim when the tire and wheel rim are supported adjacent the robot, a lubrication apparatus having a lubrication head and adapted to apply a lubrication solution to the selected one of either the tire and wheel rim while supported by the robot, and a mounting assembly configured to receive the tire and wheel rim from the robot. The mounting assembly includes a mounting support and a tire holding assembly. The mounting support includes a rim clamp assembly configured to receive and fixedly hold the wheel rim placed at the mounting support by the robot and the tire holding assembly includes movable clamps configured to hold and position the tire received from the robot. The assembly apparatus further includes a control system adapted to control the robot to select and engage one of a tire and wheel rim, move the selected tire or wheel rim to the lubrication apparatus and apply lubrication solution to one of the bead area of the selected tire or the tire bead engaging area of the selected wheel rim with the lubrication head. The control system is also adapted to control the robot to move the selected tire and wheel rim to the mounting assembly.

100111 In a further aspect of the invention, a robotic vehicle tire and wheel rim assembly apparatus comprises a multi-axis tire robot for selecting a tire supported adjacent the tire

robot, a multi-axis rim robot for selecting a wheel rim supported adjacent the rim robot, at least one lubrication apparatus having a lubrication head, and at least one mounting assembly. The lubrication apparatus is adapted to apply a lubrication solution to at least one of a tire supported by the tire robot and a wheel rim supported by the rim robot. The mounting assembly includes a mounting support and a tire holding assembly, the mounting support being configured to receive a wheel rim from the rim robot and the tire holding assembly configured to receive a tire from the tire.robot. The assembly apparatus further includes a control system adapted to control the tire robot to select and engage a tire, move the selected tire to the lubrication apparatus and apply lubrication to the bead area of the selected tire, and move the selected lubricated tire to the mounting assembly. The control system also controls the rim robot to select and engage a wheel rim, move the selected wheel rim to the lubrication apparatus and apply lubrication to the tire bead engaging area of the selected wheel rim, and move the selected lubricated wheel rim to the mounting assembly.

|OOI2| In one aspect, the invention provides a method for assembling a vehicle tire to a wheel rim comprising the steps of providing at least one multi-axis robot for selecting one of a tire and wheel rim when the tire and wheel rim are supported adjacent the robot, moving the selected one of the tire and wheel rim to a lubrication area with the robot and applying a lubrication solution by spraying the solution on one of the bead area of the selected tire or the tire bead engaging area of the selected wheel rim with a spray head, moving the selected one of the lubricated tire or wheel rim to a mounting support with the robot, and moving the other of a tire or wheel rim to the mounting support with a robot, and mounting the tire on the wheel rim to form a tire/wheel rim assembly.

(OO13| In another aspect of the invention, a method for assembling a vehicle tire to a wheel rim comprises the steps of moving the selected one of the tire and wheel rim to a lubrication area with a multi-axis robot and applying a lubrication solution to the bead area of the selected tire or the bead engaging area of the selected wheel rim, moving the selected one of the lubricated tire or wheel rim to a mounting support with the robot and moving the other of a tire or wheel rim to the mounting support, and mounting the tire on the wheel rim to form a tire/wheel rim assembly by clamping the wheel rim on the mounting support with three spaced clamping members. In addition, the tire is held in general alignment with the wheel rim while engaging the tire with the wheel rim, and the tire bead of the tire is urged over an adjacent tire bead engaging area of the wheel rim with a tire engaging tool.

100l4| In yet another aspect of the invention, a method for assembling a vehicle tire to a wheel rim includes providing at least one multi-axis robot for selecting one of a tire and a wheel rim when the tire and wheel rim are supported adjacent the robot, moving the selected one of the tire and wheel rim to a lubrication area with the robot and applying a lubrication solution to one of the bead area of the selected tire or the bead engaging area of the selected wheel rim, moving the selected one of the lubricated tire or wheel rim to a mounting support with the robot and moving the other of the tire or wheel rim to the mounting support, and mounting the tire on the wheel rim to form a tire/wheel rim assembly by clamping the wheel rim on the mounting support, holding the tire in general alignment with the wheel rim and engaging the tire with the wheel rim while restraining rotation of the tire with respect to the rolling axis of the tire, and urging the tire bead of the tire over an adjacent tire bead engaging area of the wheel rim with a tire engaging tool.

|00l 51 In related aspects of the invention, a robotic vehicle tire and wheel rim assembly apparatus includes a multi-axis robot for selecting one of a tire and wheel rim when the tire and wheel rim are supported adjacent the robot, a lubrication assembly for applying a lubrication solution to one of a tire and wheel rim while supported by the robot, the lubrication assembly including at least one spray head and a support for supporting the spray head in fixed position during spraying, a mounting assembly for mounting the selected tire or wheel rim with the other of a tire or wheel rim when supplied to the mounting assembly to form a tire and wheel rim assembly, and a control system controlling the robot to select and engage one of a tire and wheel rim at a position adjacent the robot, move the selected tire or wheel rim to the lubrication assembly and apply lubrication solution to one of the bead area of the selected tire or the tire bead engaging area of the selected wheel rim with the spray head, the control system also controlling the robot to move the selected tire and wheel rim to the mounting assembly.

100l6| In other aspects, the invention may include a mounting assembly for use with a robotic vehicle tire and wheel rim assembly apparatus wherein the mounting assembly includes a three-point clamp for clamping a wheel rim during assembly with a tire. In addition, the invention may include the use of a tire holding assembly with a mounting assembly for holding a tire in alignment with a wheel rim, the tire holding assembly including restraining members that restrain rotation of the tire about its rolling axis during assembly of the tire to the wheel rim, all in combination with a control system for controlling the robot to select the tire or wheel rim, move the selected tire or wheel rim to a lubrication apparatus,

apply lubrication solution to one of the bead area of the selected tire or the tire bead engaging area of the selected wheel rim and move the selected tire and wheel rim to the mounting assembly followed by assembly with a robot mounted tire mounting tool. In additional aspects, the robot mounted tire mounting tool may include sensors, such as optical sensors and/or load cells, for monitoring and/or evaluating the assembly of the tire to the wheel rim. Still additional aspects include monitoring loads on the multi-axis robot motors to evaluate and compensate forces associated with mounting the tire to the wheel rim.

|OOI7| In preferred forms of the invention, the tire and wheel rim assembly apparatus may include the use of three multi-axis robots, one for selecting and moving a wheel rim to the lubrication apparatus, and then to the mounting assembly, a second robot for selecting a tire from a tire input conveyor, moving the tire to the lubrication apparatus and then to the mounting assembly, as well as a third robot for moving a tire mounting tool to engage and mount the tire on the wheel rim. At least one of the robots, preferably the first wheel rim engaging robot, moves the assembled tire and wheel rim to another location after assembly, such as an inflator apparatus or balancing apparatus.

|OO18| In a preferred form of the invention, a tire input conveyor is used with the assembly apparatus including camera sensing apparatus to measure the type and dimensions of the tires on a conveyor, as well as the position of the tire to allow the tire robot to properly select and move the tire. In addition, the sensing apparatus can determine the rolling direction of the tire for proper assembly with the wheel rim.

[00191 In yet other preferred aspects of the invention, a wheel rim input conveyor can be provided with a wheel lift to allow robotic engagement and reversal of the wheel rim to enable proper assembly with an associated tire, as well as a support adjacent the tire input conveyor to allow supporting a tire for reversal to change its rolling direction prior to assembly with a wheel rim.

100201 The present tire and wheel rim assembly apparatus provides significant benefits over prior known systems. The use of multi-axis robots speeds the automated selection, transfer, lubrication and mounting of both tires and wheel rims thereby reducing cycle time and eliminating the need for cumbersome space and time consuming conventional conveyors or manual transfer methods within the lubrication and assembly area. The invention allows the assembly of a wide variety of tires and wheel rims via automated camera sensing techniques coordinated with multi-axis robots to assure the provision of the correct tire with the correct wheel rim in the correct orientation for a desired rolling direction. Premarked and

prebalanced tires and wheel rims can be aligned and assembled using the present invention in a manner preventing misalignment of the predetermined markings without the inclusion of time consuming and added alignment apparatus and processing. Further, specific cycle times for lubricating both tires and wheel rims are reduced with the present invention as compared to prior known lubricating assemblies while the use of multiple robots and multiple tire mounting stations maintains efficient and coordinated tire and wheel assembly, transfer to a subsequent inflator or balancing apparatus, if desired, and continued tire and wheel assembly on an uninterrupted basis. |002t I These and other objects, advantages, purposes and features of the invention will become more apparent from a study of the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS |0022| FIG. 1 is a plan view of a preferred embodiment of a robotic vehicle tire and wheel assembly apparatus of the present invention that is especially adapted for assembling truck tires with truck wheel rims; |00231 FIG. 2 is a end elevation of the wheel rim input conveyor included in the assembly apparatus of FIG. 1; [00241 FIG. 3 is a fragmentary plan view of the exit end of the wheel rim input conveyor shown in FlG. 2; 10025) FIG. 4 is an end elevation of the exit end of the tire input conveyor of the assembly apparatus of FIG. 1, including a tire vision system for viewing the tires when stacked on the input conveyor; 10026J FIG. 5 is a fragmentary plan view of the exit end of the tire input conveyor of FIG. 4 showing the tire vision system; [0027| FIG. 6 is an isometric view of the reject conveyor of the assembly apparatus of FIG.

1 , including a tire reversal table or support for reversing the rolling direction of tires prior to assembly;

(0028| FIG. 7 is a plan view of the tire reversal table and reject conveyor of FIG. 6;

100291 FIG. 8 is a perspective view of a multi-axis robot suitable for use with the present invention; 100301 FIG. 9 is a side elevation of the robot of FIG. 8;

|003i I FIG. 10 is an isometric view of an end effector and a portion of the robot arm for engaging and moving a wheel rim or finished tire and wheel assembly with a robot of the type shown in FIGS. 8 and 9; 100321 FIG. 1 OA is a sectional side elevation of one form of wheel rim usable with the present invention; 100331 FIG. 1 OB is a sectional side elevation of a second form of wheel rim usable with the present invention; |0034I FIG. 1 OC is a schematic illustration of the range of motion in the radial direction of the engaging rollers on the wheel rim end effector during operation of that end effector; (00351 FIG. 1 OD is a schematic illustration of the engaging rollers of the wheel rim end effector engaging the center aperture of a typical wheel rim from either the front or rear side of the wheel rim;

10036| FlG. 1 1 is an isometric exploded view of the wheel rim end effector of FIG. 10;

|0037| FIG. 12 is a sectional elevation of the wheel rim end effector of FIGS. 10 and 11 and its attachment to the wrist end of a robot arm;

|0038| FIG. 13 is an end view of the wheel rim end effector of FIGS. 10-12;

|0039| FIG. 14 is a perspective view of an alternative wheel rim end effector and a portion of the robot arm engaging a typical wheel rim from the rear side of the wheel rim; [00401 FIG. 15 is a side perspective view of the wheel rim end effector of FIG. 14 when mounted on the robot arm and in engagement with the wheel rim with a portion of the wheel rim removed for clarity; |004l I FIG. 15 A is a perspective view of the wheel rim end effector of FIG. 14 shown removed from the robot; (0042| FIG. 15B is a perspective view of the wheel rim end effector of FIG. 14 with a portion of the end effector shown in phantom to illustrate the internal arm gears and drive gear for selectively swinging the end effector gripping arms; |0043] FIG. 16 is an isometric view of a tire end effector for attachment to a robot arm of the type shown in FIGS. 8 and 9; |0044) FIG. 17 is a sectional end elevation of the tire end effector taken along plane XVII-

XVII ofFIG. 16;

|0045| FIG. 18 is a top plan view of the tire end effector of FIGS. 16 and 17;

|0046| FIG. 19 is a sectional side elevation of the tire end effector taken along plane XIX-

XIX of FIG. 18;

|00471 FIG. 20 is a sectional plan view of the tire end effector taken along plane XX-XX of

FIG. 19; 10048] FIG. 21 is a perspective view of the tire end effector of FIGS. 16-20 engaging and holding a typical vehicle tire for movement thereof; |0049) FIG. 22 is an isometric view of the lubrication apparatus of the assembly cell in accordance with the present invention showing a rim in position for lubrication; (OOSOJ FIG. 23 is a side elevation view of the lubrication apparatus of FIG. 22;

|005l I FIG. 23 A is a side elevation view of an alternative lubrication apparatus of the assembly cell in accordance with the present invention;

|0052] FIG. 24 is a top plan view of the lubrication apparatus of FIG. 22;

[0053] FIG. 25 is a front elevation view of the lubrication apparatus of FIG. 22;

[0054J FIG. 26 is an isometric view of a mounting assembly of the assembly cell of the present invention; |0055] FIG. 27 is an isometric view of the mounting support of the mounting assembly shown removed from the mounting assembly;

|0056| FIG. 28 is a side elevation view of the mounting support of FIG. 27;

|0057] FIG. 29 is a front elevation view of a tire lift of the mounting assembly of FIG. 27;

10058] FIG. 29A is a side elevation view of the tire lift of FIG. 29;

|0059| FIG. 30 is a front perspective of the tire holding assembly of the mounting assembly of FIG. 26 shown removed from the mounting assembly;

10060] FIG. 30A is a close up view of the tire holding assembly of FIG. 30;

|006l ] FIG. 31 is a rear perspective view of the tire holding assembly of FIG. 30;

|0062| FIG. 32 is a side elevation view of the tire holding assembly of FIG. 30;

|0063] FIG. 33 is a cross sectional view along the line XXXIII-XXXIII of FIG. 32;

10064 J FIG. 33A is a cross-sectional view of an alternative upper gripping roller;

|0065] FIG. 33B is a cross-sectional view of an alternative lower gripping roller;

10066] FIG. 33C is a cross-sectional view of another alternative lower gripping roller;

]0067] FIG. 34 is an isometric view of the tire pusher of the mounting assembly of FIG. 26 shown removed from the mounting assembly;

|0068| FIG. 35 is an isometric view of a tire mounting tool end effector;

10069] FIG. 36 is a side elevation view of the tire mounting tool end effector of FIG. 35;

]0070] FIG. 37 is a front elevation view of the tire mounting tool end effector of FIG. 35; and

|007l ] FIG. 38 is a top plan view of an alternative robotic tire and rim assembly cell.

DESCRIPTION OF THE PREFERRED EMBODIMENTS GENERAL OVERVIEW

100721 The present invention will now be described with reference to the accompanying figures, wherein the numbered elements in the following written description correspond to like-numbered elements in the figures. A robotic tire and wheel rim assembly apparatus or cell 10 is illustrated in FIG. 1 for mounting vehicle tires to wheels or wheel rims. The robotic tire and wheel rim assembly cell 10 includes three multi-axis robotic devices: a rim robot 20, a tire robot 30, and a mounting robot 40. Robots, 20, 30, 40 are guided and controlled by respective controls including robotic control 14 for rim robot 20, robotic control 16 for tire robot 30, and robotic control 18 for mounting robot 40 (FIG. 1). Robot control 18 for robot 40 is also linked with the four drive or servomotors 316, 318 for tire clamps 296, 298 on mounting table 80a, 80b as described more fully below. Each of the robot controls preferably includes a power supply, the servo drives for the motors on the robot, the robot control hardware and software, a tech pendant or type of programmer interface box, and I/O communication circuit boards. Each robot control 14, 16, 18 is connected to system- control 12 using the type of communication circuit boards included in the robot controls. System control 12 is preferably a programmable logic controller or PLC and communicates with robot controls 14, 16, 18 on a high level by sending and receiving parameters, signals for zone locking the robots, and the like.. Robotic devices 20, 30, 40 are adapted for moving tires, rims, and assembled wheels, as well as for mounting tires to rims, using robotic arm end effectors 160, 190 described more fully below. Robotic tire and wheel rim assembly cell 10 also includes a rim input conveyor 50, a tire input conveyor 60, a soaping or lubrication station or assembly 70, two substantially similar mounting tables 80a, 80b, an inflator assembly 90, and an assembled wheel output conveyor 95.

10073] Although described in greater detail below, the general operation of robotic tire and wheel rim assembly apparatus or cell 10 will be initially described. Rims R (FIGS. 2 and 3) are received into cell 10 on rim input conveyor 50 such that rim robot 20 is able to grasp a rim. Rim robot 20 is adapted to move the selected rim to soaping station 70 where, in the preferred embodiment, the rim is rotated by rim robot 20 proximate spray nozzles 230, 232, (FIG. 22) such that the tire bead engaging areas or tire bead engaging flanges of the rim are lubricated. The selected rim is then moved to one of the two mounting tables 80a, 80b with robot 20. After placement of the lubricated wheel on a mounting table, rim robot 20 returns to the rim input conveyor 50 to select the next rim for lubrication at soaping station 70 and

placement at the other mounting table. As noted below, prior to selecting the next rim, rim robot 20 may be used to remove an assembled wheel and tire from the other mounting table if an assembled wheel is present at the mounting table.

|0074| Simultaneously with the movement of the wheel rims, tire robot 30 is used to select, lubricate, and position for mounting tires that have been received into cell 10 along tire input conveyor 60 as stacks S of tires T. Tire robot 30 selects the top most tire T (FIGS. 6 and 7) of a stack S (FIGS. 4 and 5) and moves it to the soaping station or lubricating assembly 70, where the beads of the tire are lubricated via rotation of the tire by tire robot 30 using tire end effector 190 proximate the spray nozzles 230, 232. The lubricated tire is then moved to the mounting table at which the first lubricated rim was previously placed and mounting robot 40 is used to assemble or mount the tire to the rim to form an assembled wheel W (FIG. 1). While the mounting robot 40 is operating at the mounting table, the tire robot 30 returns to the tire input conveyor 60 to select the next tire T for lubrication at soaping station 70 and placement at the other mounting table. Rim robot 20 is also adapted to remove the assembled wheel W from the mounting table and place the assembled wheel onto inflator assembly 90 prior to selecting the next rim.

|00751 As also described in more detail below, tire and wheel rim assembly apparatus or cell

10 includes additional equipment and operations, including a tire vision system 120 on tire input conveyor 60 and a rim vision system 115 on rim input conveyor 50, as well as a tire inflation apparatus 90 on assembled wheel output conveyor 95, and a reject conveyor 100. It should also be appreciated that alternative robotic tire and wheel rim assembly cells, such as automobile tire and wheel rim assembly cell 400 shown in FIG. 38, may be constructed in accordance with the present invention. For example, as described more fully below, robotic wheel assembly cells may include more or fewer robots, or a robotic device may be constructed to grasp and move both tires and rims, as well as assembled wheels. WHEEL RIM INPUT CONVEYOR AND LIFT TABLE

[0076| Referring to FIGS. 1-3, rim input conveyor 50 is shown to be a roller conveyor, which rollers may be powered or gravity rollers. Rim input conveyor 50 may alternatively be a belt conveyor or the like. In the illustrated embodiment, a rim R travels along rim input conveyor in the direction of the arrow in FIG. 1 while positioned on its side until it reaches the conveyor output end. The output end includes a vertical lift table 110 (FIGS. 2 and 3) and a rim vision system 115. Rim vision system 115 is used to determine whether the correct rim is positioned at output end for a given application, and whether the exterior surface or side or

interior surface or side of a rim is facing upwards. Rim vision system 115 may include one or more cameras, and/or other types of detecting or sensing equipment, such as proximity switches or the like, that are oriented to look at particular features of a rim. Rim vision system 115 may also include a separate electronic control device, which may be interfaced with the system control 12. The orientation of the rim is determined because certain rim styles require the tire to be assembled to the rim from only one of either the exterior or the interior surface sides and, therefore, must be grasped by the rim robot 20 in a particular manner to properly place the wheel rim onto one of the mounting tables 80a, 80b.

(00771 In the illustrated embodiment, rims are intended to be supplied into cell 10 along rim input conveyor 50 with either side of the rim facing upwards such that the rim robot end effector 160 may grasp the rim from above, as described in more detail below. However, in the event rim vision system 115 determines that a rim at the output end of conveyor 50 is positioned with the desired side facing downward toward the conveyor rollers, which occurs often based on somewhat random placement of the rims on conveyor 50, vertical lift table 110 (FIGS. 2 and 3) is adapted to raise the rim via a linear drive unit 112 incorporating an electric drive motor 114. When lift table 110 is in its elevated orientation (FIG. 2), rim robot 20 is able to engage and grasp the rim from below (FIGS. 14 and 15) such that, when placed on a mounting table 80a or 80b, the desired rim side is facing upwards. In the event rim vision system 115 determines that an incorrect or defective rim has been supplied along rim conveyor 50, rim robot 20 may be used to grasp the defective rim and move it to the reject conveyor 100.

TIRE INPUT CONVEYOR AND TIRE VISION SYSTEM

100781 Referring now to FIGS. 1, 4 and 5, tire input conveyor 60 also includes a roller conveyor, having rollers may be powered or gravity rollers. Tire input conveyor 60 may alternatively be a belt conveyor or the like. In the illustrated embodiment, as previously noted, tires enter cell 10 in a stacked arrangement in the direction of the arrow in FIG. 1 , with the tires laying on their sidewalls in a horizontal orientation to form a generally vertically upwardly extending cylindrical stacks. For example, tires may enter cell 10 in stacks of two to five tires.

J0079J Tire vision system 120 is positioned at output end 62 of tire input conveyor 60. Tire vision system 120 includes a generally L-shaped frame work 126 to which are mounted first and second cameras 122, 124, a lighting member 128, and laser line lighting modules 129. Frame work is adapted to be vertically positioned via an electric drive motor 130 along track

mounted to vertical post 132, with FIG. 4 illustrating frame work 126 in three different vertical positions A, B or C relative to the rollers of tire input conveyor 60. Lighting member 128 includes light projecting elements, such as lighting emitting diodes (LED's), for illuminating the stacked tires S for proper visualization by first and/or second cameras 122, 124. Lighting member 128 is only operational when second camera 124 takes an image of the tread pattern on the tires. However, laser modules 129 project laser lines 129a (FIGS. 4 and 5) on the upper sidewall of the top tire in stack 5. The laser lines appear in the image taken with first camera 122, and are used in the control algorithm of system control 12 to determine the top tire position, angles of rotation relative to a horizontal plane, inner tire diameter, and outer tire diameter.

|0080| In the illustrated embodiment, first camera 122 of tire vision system 120 has a downwardly angled field of view 123 directed toward the stack of tires S. Second camera 124 is directed horizontally toward the same stack of tires. First and/or second camera 122, 124 may initially be used to detect the presence of the stack S of tires at output end 62. First camera 122 is also used for determining or establishing the coordinates or position of the top most tire to enable tire robot 30 to select the top most tire in stack S. First camera 122, in coordination with the control system computing device 12 of cell 10 (FIG. 1), such as a programmable logic controller (PLC), determines the outside diameter, inside diameter, and center axis or rolling axis location of the top most tire T, and may also determine the relative angle of the plane defined by the upwardly facing tire sidewall of the top most tire, via triangulation calculations. Based on these calculations, the cell 10 control system or computing device 12 is able to control and direct tire robot 30 to the proper location at which to grasp the top most tire using the tire end effector 190 (FIGS. 16-21), which is described in detail below.

|00811 Second camera 124 is used to ensure that the selected tire is properly oriented for mounting to the rim such that the tire, after it has been mounted to the rim, has the proper rolling direction. Certain tires, such as specially configured front truck tires with anti-splash deflectors, rear truck tires where the rear axle is powered, and most automobile tires for rear and front axles, are typically constructed to have a particular rotation direction for proper traction, such as in wet and/or snowy conditions, or a sidewall that must face outwardly. Therefore, it is important that the tires be mounted to the rims with the proper rolling direction directed toward the forward rolling direction of the vehicle to which it is mounted or the proper sidewall facing outwardly. In the illustrated embodiment, the proper rolling

direction or required outer sidewall of a tire may be determined using second camera 124. After a tire has been grasped by tire robot 30, tire robot 30 positions the tire in front of second camera 124 to ensure such that second camera 124 is able to properly image the tread pattern or outer sidewall of the selected tire. Second camera 124 in conjunction with a computational device such as system control computer or PLC 12, may be used to search for and detect particular tread pattern features, such as the "V" pattern of the treads, to verify the tire rolling direction or special outer sidewall constructions.

|0082| In the event second camera 124 determines that the rolling direction of a tire that has been grasped by tire robot 30 is oriented improperly for mounting to a rim, the tire may be turned over, flipped or reversed using turn table 130 mounted to the input end 116 reject conveyor 100. As shown in FIGS. 6 and 7, turn table 130 comprises a generally rectangular frame 132 that is supported above input end 116 of reject conveyor 100 and forms a central opening 134. A tire requiring reversal or flipping may be placed onto frame 132 by tire robot 30 and released such that the tire is supported by turn table 30. Tire robot 30 may then be used to re-grasp the tire from beneath through the central opening 134 of frame 132 whereby tire robot 30 is able to flip and reverse the tire for mounting to a wheel located at a mounting table 80a, 80b with the tire properly oriented relative to the tire's rolling direction.

|00831 It should also be appreciated that alternative methods and/or structure may be used to grasp a tire or wheel in the proper orientation. For example, if tires were supplied into a robotic wheel assembly cell without being stacked, a vertical lift table could be incorporated into tire input conveyor 60 to enable a tire robot to grasp the tires from below in similar manner to lift table 130 of rim input conveyor 50. Similarly, an alternative turntable, or even turn table 130 mounted to reject conveyor 100 and described above for use with tires, could be used for reversing or flipping rims in like manner to the process described above for reversing tires.

MULTI-AXIS ROBOTS

|0084| As shown in FIGS. 8 and 9, in the preferred embodiment of tire and wheel rim assembly apparatus or cell 10, each of the robots 20, 30 and 40 is a precision, heavy payload, high-speed, six axis, electric, servo-driven robot preferably obtained from Fanuc Robotics (U.K.) Limited of Whitley, Coventry, England, under Model No. M-900iA Series. Each robot is preferably controlled by a robot control dedicated to that robot. As mentioned above, these include robotic controls 14, 16, 18 for rim robot 20, tire robot 30 and mounting robot 40, respectively. Each robot preferably includes a base 140 on which is mounted a support

142 rotatable on vertical axis 143. Upstanding support 144 is mounted for pivotal movement about horizontal axis 146 with respect to support 142. A robot arm 147 is pivotally mounted about horizontal axis 148 at the upper end of support 144. Arm 147 receives a wrist assembly 152. Wrist assembly 152 is rotatable on longitudinal axis 150 of arm 147 and includes a pivot axis 154 and a circular mounting flange 156 adapted to receive and secure a variety of different grippers or holders to be used by the robot for grasping and moving a variety of goods. In addition, flange 156 is rotatable with respect to wrist 152 along an axis 158 which extends perpendicular to axis 154.

ROBOTIC WHEEL RIM END EFFECTOR OR RIM GRIPPER

[0085| As shown in FIGS. 10-15, wrist assembly 152 of wheel rim robot 20 is adapted to receive a gripping assembly or end effector or rim end effector, such as end effector 160 of FIGS. 10-13 and/or end effector 160' of FIGS. 14-15B ₅ which are especially adapted to engage, secure, lift and move a variety of types and sizes of vehicle wheel rims by their center or axle receiving apertures. Depending on the size of the wheel rim to be grasped, an end effector may alternatively grasp a wheel rim by engaging the inner circumference of the peripheral flange of the wheel rim, either from the back or the front of the wheel rim. Two examples of the many varieties of wheel rims with which end effector 160 can be used are shown in FIGS. 1OA and 1OB.

10086) Referring to FIGS. 10- 13 , the gripper or end effector assembly 160 is bolted to circular disk or flange 156 on robot wrist 152 and includes a pneumatic motor 162 secured to circular plate 164 and adapted to rotate a central shaft 166 in both rotational directions. Alternatively, hydraulic, servo electric or electric motors could be used in place of pneumatic motor 162. The rotational angle is read by a rotative encoder 163 (FIG. 11) electrically connected to the robot control 14 and included with motor 162 indicating whether the end effector clamp is open or closed and verifying the type of rim when compared to the diameter of the rim central aperture and flange thickness stored in the rim robot control 14 or system control 12. Shaft 166 extends toward the free end of the gripper assembly. Fixed to shaft 166 is a camming plate 168 including a series of curved, camming slots 170 which are aligned with curved openings 174 in cover plate 172 telescoped over shaft 166 and adapted to cover camming plate 168. Pivotally mounted on plate 172 are a series of pivot arms 176, preferably three in the preferred embodiment, each including a pivot axis 178. Cam followers 180 on each of the pivot arms 176 extend through openings 174 to engage cam slots 170 in camming plate 168. At the outer end of each of pivot arm 176 is a wheel rim

engaging rollers 182. Rollers 182 each have a truncated hourglass shape including a V- shaped groove at its midpoint as best seen in FIG. 12. A cover 184 extends from disk or flange 156 over motor 162, plate 164, and camming plate 168. Cover plate 172 abuts the outer end edge of cover 184 as shown in FIG. 10.

100871 Operation of pneumatic motor 162 rotates shaft 166 and camming plate 168 in one rotational direction (clockwise in FIG. 11) thereby moving cam followers 180 in slots 170 causing pivotal movement of pivot arms 176 about pivots 178. As shown in FIG. 1OC, such action causes each of the rim engaging rollers 182 to move simultaneously radially outwardly such that the rollers define an increasingly larger circumference allowing gripper or end effector 160 to engage central axle openings of various wheel rims having different diameters. As also shown in FIG. 10D, end effector 160 may be received by and engaged with wheel rims R via rollers 182 from either the front surface Ri or rear surface R ₂ (FIG. 14) of the wheel rim. As shown in FIG. 10D, the edge of the central aperture in any wheel rim is adapted to be received in the V-groove of rollers 182 with motor 162 urging the pivot arms and thus rollers 182 outwardly with sufficient force to retain the wheel aperture edge securely in the rollers. This V-shape engagement allows the robot to lift and support the axial load of the wheel rim. The air or other fluid in motor 162 is held and locked so that rollers 182 remain engaged and clamped with the wheel rim aperture edge even if the supply of air is interrupted. After such clamping engagement, the position of the wheel rim with respect to robot flange 156 is precisely known to rim robot control 14 allowing robot 20 to accurately position the wheel rim for the various tire and wheel rim assembly functions. The synchronous movement of rollers 182 also positions the center or rolling axis of rim R with the center axis of end effector 160 facilitating precise location of rim R by robot 20 in the various subsequent assembly functions. Rotative encoder 163 can be used to measure the diameter of the center bore of rim R when the thickness of the disc in which the bore is formed is known, or can be used to measure the disc thickness when the center bore diameter is known. Opposite rotation of shaft 116 by motor 164 causes inward radial movement of rollers 182 to release the wheel rim aperture when desired. Rollers 182 are preferably formed from one of three preferred materials including ultra high molecular weight polyethylene (UHMW PE), aluminum, or aluminum with a layer of polyurethane elastomer, preferably that sold under the trademark Vulkolan, available from VulkoprinNV of Tielt, Belgium.

[0088] End effector 160' of FIGS. 14-15B is of generally similar construction to end effector

160 of FIGS. 10-13 such that not all of the like features or components or alternatives will be

discussed herein. In contrast to end effector 160, end effector 160' is configured for grasping a wheel rim by the inner circumference of the peripheral flange of the wheel rim. End effector 160' includes three gripping arms 177, each of which includes an arm end member or wheel engaging member 183 that may be formed of similar materials as that of rollers 182 of end effector 160 discussed above, with arm end members 183 adapted to contact a wheel that is to be moved. Each gripping arm 177 is attached to an arm gear 185, with each arm gear 185 in turn operatively engaged and driven by a central drive gear 187 that is selectively rotated by a rotary pneumatic motor 162'. As discussed below, each gripping arm 177 is operatively mounted to the center of an arm gear 185 whereby rotation of the arm gear 185 causes the respective gripping arm 177 to rotate or swing.

|0089| In operation, wheel rim robot 20 positions end effector 160' within the interior flange area of a wheel rim, such as from the back side of the wheel rim, with the gripping arms 177 retracted in the position illustrated in FIGS. 15A and 15B. Pneumatic motor 162' then rotates central drive gear 187 in a first direction to cause arm gears 185 to simultaneously rotate and in turn outwardly swing gripping arms 177 beyond the cylindrical circumference of end effector 160', as shown in phantom in FIG. 15A. Rotation of arm gears 185 causes arm end members 183 to engage the inside diameter of the wheel, as shown with wheel R in FIG. 15, such that the wheel is engaged by the end effector 160' and may be moved by the rim robot 20. Upon relocation of the wheel by rim robot 20, pneumatic motor 162' rotates central drive gear 187 in the opposite direction to cause gripping arms 177 to swing inwardly and release the wheel. In the illustrated embodiment, arm end members 183 are rounded to aid the grasping of wheels of various inner diameters, with the range of radial movement of gripping arms 177 selected to enable wheels of various inside diameters to be grasped. ROBOTIC TIRE END EFFECTOR OR TIRE GRIPPER

|0090| As shown in FIGS . 16-21 , a tire gripper assembly or tire end effector 190 is adapted to be mounted on flange 156 of multi-axis tire robot 30. Tire end effector 190 includes an elongated, rectangular base plate 192 on which are secured a pair of spaced, parallel, truncated, trapezoidal, upstanding walls or flanges 194 extending along the length of plate 192. Located centrally and extending between walls 194 are a pair of parallel bracing members 196 each being spaced above the top surface of plate 192. Secured intermediate walls 194 and brace members 196 is a generally circular securing plate 198 adapted to be bolted to flange 156 of wrist assembly 152 of tire robot 30 such that the tire end effector 190 can be moved in unison with the robot arm 147 and wrist assembly 152.

On the opposite side of plate 192, are mounted a pair of rectangular slide members

200 which are adapted for longitudinal movement toward and away from one another and the center of plate 192 on tracks 202. Each slide member 200 includes a pair of spaced outwardly extending tire gripping posts 204. Each post 204 has a ribbed configuration including a plurality of annular ribs adapted to engage, secure and grip the tread area of a tire to be transported by the tire end effector as is best seen in FIG. 21. Slide members 200, and thus, each pair of tire gripping posts 204 is moved toward and away from one another by a pair of spaced, parallel, pneumatic fluid cylinders 208a, 208b operating extending rods or shafts 210a and 210b. Preferably, each fluid cylinder 208a, 208b is comprised of a pair of back-to-back fluid cylinders mounted co-axially with one another as shown in FIG. 20, one . fluid cylinder in each of the back-to-back pairs being longer and providing greater shaft movement than the other fluid cylinder. Alternatively, a spindle or screw drive with electric motor or hydraulic cylinders can be used in place of the pneumatic fluid cylinders. One shaft from each fluid cylinder is secured to a fixed mount 212. Mounts 212 are positioned at opposite ends of the underside of plate 192. The opposite ends of shafts 210a, 210b are secured to slide members 200 via connections 214. A pair of longitudinally extending, opposed slots 216 are provided through plate 192 such that connections 214 from slide members 200 extend therethrough for connection to a synchronizing linkage 218 (FIG. 18). Linkage 218 includes a center link 222 (FIGS. 16 and 18) pivotally mounted on a shaft 220 located at the center of plate 192. Opposite ends of center link 222 are pivotally secured to synchronizing links 224 which extend from the center link to the respective connections 214 to slide members 200 where they are likewise pivotally secured. Operation of fluid cylinders 208a, 208b, and thus movement of slide members 200 and tire gripping posts 204, is coordinated by a tire robot controller 16 (FIG. 1) based on the outer diameter of the tire as measured by the tire vision system at the end of tire input conveyor as described above. When the tire size is communicated to the tire robot controller 16, and end effector 190 is positioned over the top most tire T on tire input conveyor 60 such that the plane of the tire sidewalls is generally parallel to plate 192, fluid cylinders 208a, 208b are activated to withdraw shafts 210a, 210b thereby drawing slide members 200 inwardly toward the center of plate 192 and shaft 220 as coordinated by synchronizing linkage 218 such that each slide member moves the same distance. Back-to-back fluid cylinders 210a, 210b are provided so that, depending on which fluid cylinders are activated, the shafts can be withdrawn in differing amounts based on the size of the tire to be gripped and moved as sensed by the tire

vision system. Cylinders 210a, 210b are positioned back-to-back to provide four fixed positions of the sliding members 200 relative to each other selectable by applying pressure to the right chambers of the cylinders. Of these four fixed positions, only the two positions with the largest relative distance of the sliding members are used and they are used for pre- positioning of gripper posts 204. Pre-positioning is done to minimize the movement of tire gripper posts 204 when picking up a tire. Immediately before picking up a tire, tire posts 204 are pre-positioned to the next larger diameter pre-position than the measured outer diameter of the tire being picked up. Then gripper assembly 190 is positioned above the tire ready for pickup. Thereafter sliding members 200 are forced toward each other by the pneumatic cylinders, thereby clamping the tire. Normally the position of sliding members 200 with the clamped tire does not correspond to one of the pre-positions. With a tire clamped inside the four gripper posts 204, the position of the sliding members can be used to measure the outer diameter of the tire with a linear position encoder 226 included on gripper plate 192 (FIG. 20). As slide members 200 are moved inwardly toward the center of plate 192, tire gripping post 204 and annular ridges 206 thereon come into contact with the tread area of tire T to firmly and securely grip the tire such that the robot arm 147 with wrist assembly 152, tire end effector 190 and tire T can be moved in unison to the lubrication apparatus 70 and then to one of the tire and wheel rim mounting stations 80a, 80b as described more fully below. I0092J Alternately, tire end effector 190 can be revised to include two additional sets of engaging posts 204' on the inner ends of slides 200 as shown in phantom in FIG. 19. Alternate posts 204' are shorter than posts 204, have a truncated hour-glass shape as shown, and are adapted to engage either the edge of the center aperture of rim R or the outer most edges of the rim R located adjacent the tire bead engaging areas of bead flanges 252a, 252b. In such case, the position of the fluid cylinders 208a, 208b could be revised to allow greater movement of slides 200 so that the additional posts 204' can be either brought closer to the center of plate 192 or extended further out than in embodiment 190. In the case of engaging the center aperture of rim R, posts 204' could be inserted within the center aperture of a wheel rim R, preferably from the front or exterior side of the wheel rim, with the fluid cylinders actuated to move slides 200 outwardly bringing posts 204' into engagement with the edge of the center aperture in the wheel rim so that the rim is firmly secured by the end effector for lifting and movement therewith. In the case of engaging the outermost diameter edge flanges of rim R, posts 204' could be extended beyond the upper edge, preferably from the front or exterior side of the wheel rim, with the fluid cylinders actuated to move slides 200 inwardly

bringing posts 204' into engagement with the outermost edge flange within the reduced diameter portion of posts 204'. The revised end effector including additional posts 204' could also be used for engaging and moving tires since posts 204' would be received in the center opening of the tire and would not contact or engage the tire beads when the outermost posts 204 engage the tread area of the tire. Hence, the revised end effector 190 could be used to engage and move either tires or wheel rims depending on the specific function desired.

LUBRICATION APPARATUS

|0093] Referring now to FIGS. 22-25, soaping station or lubrication apparatus 70 is shown with a rim R illustrated in position to be lubricated by lubrication apparatus 70. Although not shown, the above described rim robot 20 and rim end effector 160 are used to position rim R into the appropriate position as depicted. In addition, as described in more detail below, rim robot 20 and rim end effector 160 are used to rotate rim R while lubrication is applied thereto. Although not shown, tire robot 30 and tire end effector 190 operate to provide lubrication to the tire beads in similar manner to that which will be described for the illustrated rim R.

10094J In the illustrated embodiment, lubrication apparatus includes a lubrication head or lubrication member having a fixed nozzle or spray head or spray nozzle 230 and a moveable nozzle or spray head or spray nozzle 232. Movable nozzle 232 is mounted on an extension member 234 driven by a motor 236. Lubrication apparatus 70 further includes a backstop 238, a drip tray 240, and a drain valve 242.

|0095| Fixed nozzle 230 is spaced above drip tray 240 by a post 246 at a known elevation programmed into or known by the system controller 12. It should be appreciated, however, that fixed nozzle 230 may be constructed to enable manual adjustment of the fixed nozzle 230 with respect to the drip tray 240 by, for example; enabling post 246 to be vertically moved up or down. In such a configuration the orientation or position of fixed nozzle 230 may be supplied to or known by the system controller 12.

|0096| Movable nozzle 232 is adapted to be adjustably spaced relative to fixed nozzle 230.

In the illustrated embodiment, extension member 234 is a linear drive unit, such as a screw drive. Extension member 234 is selectively extended or retracted via motor 236, which receives signals from the system controller 12 based on the particular dimensions of the rim (or tire) positioned at lubricating apparatus 70, as described below. A stop member 248, shown constructed as angular bracket, is affixed to extension member 234. Stop member 248 is adapted to contact a corresponding stop 250 affixed to post 246, thereby establishing a minimum distance to which the nozzles 230, 232 may be spaced.

|0097| Fixed nozzle 230 and movable nozzle 232 are adapted to spray a lubrication solution onto rim R, and are spaced and directed to simultaneously or independently spray the solution at both of the bead flanges 252a, 252b of rim R in an approximately 1 inch to 2 inch wide zone. The lubrication solution may be a soap based solution and is intended to aid movement of the tire T over the rim R when being mounted to the rim R, and is also intended to enable the tire beads to properly seat on the rim R when being inflated at the inflation apparatus 90. The illustrated rim R of FIGS. 22-25 is intended for use in large truck applications. It should be appreciated, however, that numerous alternative rim styles and associated tires may be handled by a robotic tire and wheel rim assembly cell in accordance with the present invention.

[0098| The system controller 12 receives positional information from rim robot 20 such that system controller 12 is able to detect or know when a rim R is properly positioned at the lubrication apparatus 70 in front of fixed and movable nozzles 230, 232. Upon detecting that a rim R is so placed, system controller 12 initiates flow of the lubrication solution through one or more supply lines via a pump (not shown) to nozzles 230, 232. Compressed air may also be forced through the nozzles 230, 232 to assist in the application of the solution to the rim R by, for example, providing force and/or atomization to the solution. Approximately simultaneously with the initiation of the spraying of the solution from nozzles 230, 232, rim robot 20 is caused to rotate rim R such that the solution may be applied about the entire circumference of both bead flanges 252a, 252b of rim R.

10099J In the illustrated embodiment, rim R is maintained at a generally constant distance from fixed and movable nozzles 230, 232 while being rotated at lubrication station 70 such that a uniform application of lubrication solution is applied to rim R. It should also be appreciated that numerous arrangements for application of the solution may be employed. For example, rim robot 20 may be caused to begin rotating rim R prior to initiating spraying of lubrication solution. Rim R may also be rotated in more than a complete revolution such as, for example, in two complete revolutions.

(001001 Backstop 238 and drip tray 240 of lubrication apparatus 70 are used to collect and prevent overspray from nozzles 230, 232 and/or lubrication solution that drips from rim R from being dispersed in the vicinity of lubrication apparatus 70. Correspondingly, drain valve 242 may be used to periodically drain collected overspray arid/or collected drips of lubrication from rim R and tires T.

1001011 Although not shown, lubrication apparatus 70 may operate in conjunction with tire robot 30 and tire end effector 190 to lubricate the inner tire beads of a tire T in similar manner to the above described lubrication of bead flanges 252a, 252b of rim R. In the case of a tire T, however, the tire T is positioned at lubrication station 70 such that extension member 234 is located within the central opening of the tire T and nozzles 230, 232 are located within the inside diameter of the tire T.

[00102] Additionally, movable nozzle 232 is spaced apart from fixed nozzle 230 such that lubrication solution sprayed from fixed nozzle 230 is directed at one tire bead and lubrication solution sprayed from movable nozzle 232 is directed at the other tire bead. Upon receiving an appropriate signal from tire robot 30 that tire T is properly positioned at lubrication apparatus 70, system controller 12 may initiate the spraying of the lubrication solution from nozzles 230, 232 and initiate rotation of tire T by tire robot 30. Tire robot 30 and tire end effector 190 maintain the tire beads of the tire T at a generally constant distance from nozzles 230, 232 to aid a uniform application of lubrication solution to tire beads.

[001031 Although the illustrated lubrication apparatus 70 is shown to include only two spray nozzles 230, 232, which nozzles are generally vertically aligned as shown in FIG. 25, alternative arrangements and numbers of nozzles may be employed within the scope of the present invention. For example, a lubrication apparatus may employ two fixed nozzles and two movable nozzles that are fixed together such that they move simultaneously. In such an arrangement, each pair of fixed and movable nozzles may include one nozzle that is directed at a negative angle and the other at a positive angle with respect to a horizontal plane. Such an arrangement of angled nozzles may, for example, aid lubrication to surfaces of rims and tires that are not perpendicular to the spray nozzles and/or provide lubrication to portions of a tire sidewall. Alternatively, a lubrication apparatus may be constructed that includes nozzles that are able to move relative to a retained rim or tire. For example, a rim or tire may be held stationary while the nozzles are caused to rotate there around or there within. Still further, it should also be appreciated that a lubrication apparatus may be constructed to include multiple nozzles where, for example, spraying from the nozzles may affect lubrication of a tire or rim without rotation of the tire or rim or nozzles, or with less rotation of the tire or rim. A lubrication station may also employ separate nozzles for lubricating a rim or a tire. In addition, more than one lubrication station may be used to lubricate tires and/or rims, which, for example, may improve the cycle time of the operation. Lubrication solution may also be applied to additional or alternative areas of a rim and/or tire. For example, the central

location between the two bead flanges of a rim may also receive lubrication to add assembly of certain types of tires onto the rim, such as, for example, "run flat" type tires and/or low sidewall profile tires.

|00104| As previously noted, the movable nozzle 232 is spaced from the fixed nozzle 230 to properly lubricate the bead flanges 252a, 252b of a rim R and/or the tire beads of a tire T, this spacing being controlled by the system controller 12. The system controller 12 may include, for example, a database, or a look-up database, including various parameter and positional information regarding operation of the assembly cell 10. One such parameter that may be stored in the database is the proper nozzle spacing required based on the type or model of rim or tire to which the lubrication solution is to be applied at the lubrication station. The type of rims and tires that are being assembled within the assembly apparatus may be input into the system controller, for example, by a keypad, touch screen, bar code reader, or the like. Alternatively, the rim vision system 115 and/or tire vision system 120 may be used to determine the particular model or type of rim or tire. For example, the vision systems may be configured to detect identifying characteristics of the tires and/or rims that are being input to the system. Still further, a vision system may alternatively be used to actually measure or determine the correct location for application of the lubrication solution by, for example, measuring the width of a rim or the spacing of the tire beads, or orienting based on a detected tire or wheel feature.

[00105| Still further, the assembly may include proportional pressure regulator valves (not shown) for controlling atomizing air output pressure from soap nozzles 230, 232, and a proportional pressure regulator valve (not shown) or other flow rate regulator to control the flow rate of the soap solution to nozzles 230, 232. These parameters can also be stored and retrieved from in the look-up database of system control 12 during operation.

[00106| Alternately, other methods of applying soap or lubrication to the tire beads or rim flanges may be used. For example rotating brushes engaged with the tire bead or rim flanges and to which the lubrication solution is fed or pumped, fixed brushes to which lubrication solution is fed or pumped and against which the tire beads or rim flanges are rotated, or fixed or rotating sponges brought in contact with the rotating or fixed tire beads or rim flanges may also be used.

[00l07| As illustrated in FIG. 23A, an alternative lubrication apparatus 70' may employ a non-spraying lubricating head or lubricating member 253, which may be formed as a fixed or rotating brush, or sponge, or the like, to which a soap solution is fed or pumped. Tire beads

or rim bead flanges may then be brought into contact with the lubricating member 253. In the case of a tire, the central opening of the tire may be placed by tire robot 30 about the lubricating member 253 such that the lubricating member 253 contacts the tire beads. The tire may then be rotated by the tire robot 30 against the lubricating member 253 so that the entire circumferences of both tire beads are engaged and lubricated. Similarly, the bead flanges of a rim may be brought into contact with the lubricating member 253 by rim robot 20 and the rim rotated against the lubricating member 253 by rim robot 20.

|00108| Still further, it should be appreciated that either the rim and/or tire may be lubricated prior to being selected by a rim robot 20 or tire robot 30. Examples of such lubrication techniques are disclosed in United States Patent No. 6,209,684 issued to Kane et al. for a Tire Bead Soaper and United States Patent No. 6,1 19,814 issued to Kane et al. for a Wheel Rim Soaper, both of which are assigned to the Burke E. Porter Machinery Co. of Grand Rapids, Michigan and are hereby incorporated herein by reference in their entireties.

TIRE MOUNTING APPARATUS

[001O9] Referring now to FIGS. 26-34, a mounting assembly or tire mounting table 80 is shown to include a mounting support or base 254 and a tire holding assembly or clamp assembly 256. As described in more detail below, mounting assembly 80 is used to assemble a tire T to a rim R in conjunction with the mounting robot 40, with the mounting support 254 adapted to secure a rim R during mounting and the tire clamp assembly 256 adapted to hold and assist mounting of the tire T onto the rim R while a mounting tool end effector 260 (FIG. 35) affixed to mounting robot 40 is used to guide the tire beads of the tire T over a flange of the rim R.

A. Mounting Support

100110) Referring to FIGS. 27 and 28, mounting support 254 is shown removed from mounting table 80 and in the embodiment illustrated includes a rim clamp assembly 264 having a fixed clamping member 266 and two movable clamping members 268a, 268b driven by a clamp drive mechanism 258. Mounting support 254 also includes a tire lift 262, described below. Fixed clamping member 266 includes two support blocks 270 surrounding a clamp jaw 272. Each movable clamping member 268a, 268b includes a single support block 274a, 274b and a clamp jaw 276a, 276b, with the two movable clamping members 268a, 268b being generally mirror images from each other. Movable clamping members 268a, 268b are mounted to a slide 278, with mounting support 254 including channels 280

within which slide 278 is adapted to move such that movable clamping members 268a, 268b may be positioned or moved toward or away from fixed clamping member 266.

(001111 Mounting support 254 further includes a clamp drive mechanism, which in the illustrated embodiment is shown as a pair of pneumatic cylinders 282a, 282b mounted in a back-to-back relation. Pneumatic cylinders 282a, 282b are used to drive movable clamping members 268a, 268b toward and away from fixed clamping member 266. One end 284 of the pneumatic cylinders 282a, 282b is affixed to a stationary plate 286 of the mounting support 254 and, as shown in FIG. 28, the opposite end 288 of the pneumatic cylinders 282a, 282b is affixed to the slide 278. In the illustrated embodiment, the two pneumatic cylinders 282a, 282b have different stroke lengths from each other whereby four different positions of the movable clamping members 268a, 268b relative to the fixed clamping member 266 may be obtained. The four positions being established based on whether both or one of the pneumatic cylinders 282a, 282b is extended or retracted.

|00i 12| In operation, as previously noted, the type of rim R is known by the system controller

12. In addition, the rim robot 20 provides positional data to the system controller 12 establishing the location at which the rim R is located as it is being moved by the rim robot 20. After the rim R is lubricated in the manner described above, rim robot 20 moves rim R to mounting support 254. System controller 12 causes movable clamping members 268a, 268b to open sufficiently based on the diameter of the rim R being transported to mounting support 254. Rim robot 20 then positions rim R onto mounting support 254 such that the rim R is supported on the support blocks 270 of the fixed clamping member 266 and on the support blocks 274a, 274b of the movable clamping members 268a, 268b. Based on the positional signal from rim robot 20 transmitted to system controller 12, system controller 12 may then cause movable clamping members 268a, 268b to move toward fixed clamping member 266, whereby jaw 272 of fixed clamping member 266 and jaws 276a, 276b of movable clamping members 268a, 268b securely hold the rim R in position on mounting support 254 (FIG. 28). Preferably, when rim R is positioned in this manner, jaw 272 is aligned with a diameter of rim R, while movable jaws 276a, 276b are spaced from one another and are equally spaced on either side of that same diameter of rim R. This provides a secure three-point clamping of the lowermost rim bead flange 252a or 252b of rim R that is maintained during mounting of tire T over the uppermost bead flange 252a or 252b that is not being clamped.

[00113] In the embodiment described above, system controller 12 is used to provide actuation signals to effect travel of the movable clamping members. Alternatively, however, a

controller or PLC or either rim robot control 14 or mounting robot control 18 may be used to control actuation of pneumatic cylinders for clamping and unclamping a rim. Cylinders 28a, 28b may be replaced by an electric motor with spindle screw or by hydraulic cylinders similarly positioned back-to-back (not shown). Fixed proximity detection with moving flag or marker is used to detect the four positions of the cylinders in logic controller 12. Alternately, a linear encoder (like encoder 226 above) or other methods could also be used. A linear encoder would also allow measurement of the rim diameter. This can be an error- proofing feature when, for example, mounting tables 80a, 80b are loaded with soaped rim and tire manually by an operator. In such case, the diameter of the supplied rim to the mounting table is not detected earlier in the process.

100114 J Referring now to FIGS. 26 and 29-29A, mounting support 254 also includes a tire lift

262. Tire lift 262, as described in more detail below, is adapted to extend vertically upwards to engage a sidewall of tire T and tilt one side or section of a tire T positioned at mounting table 80 and correspondingly lower the directly opposite side or section of tire T that is positioned 180° opposite the section being lifted for assisting assembly of the tire T to the rim R. Tire lift 262 includes a pair of tire engaging blocks 290, a bracket 292 for affixing to mounting support 254, and a lift cylinder 294 for extending and retracting tire engaging blocks 290. In the embodiment shown, lift cylinder 294 is a pneumatic cylinder. However, lift cylinder 294 may alternatively be constructed as a hydraulic cylinder or as an electric drive.

B. Tire Holding Assembly

[00115| Referring now to FIGS. 30-34, the tire holding assembly 256 shown includes a pair of tire clamps 296, 298 that are movable within a frame 300 having vertically extending channels 302. Tire holding assembly 256 also includes a tire pusher 304 (FIGS. 26 and 34), which is adapted to be mounted to one of the tire clamps 296, 298 as shown in FIG. 26. As described in more detail below, tire holding assembly 256 is adapted to receive a section of a tire T within tire clamps 296, 298 provided from tire robot 30 and is used in conjunction with mounting end effector 260 and mounting robot 40 to assemble the received and clamped tire T to a rim R secured on mounting support 254.

|00l 16| Tire clamps 296 include an upper tire clamp 296 and a lower tire clamp 298. Upper tire clamp 296 includes an upper sliding bracket member 306 extending between and slidably supported within channels 302, and an upper clamping jaw 308 extending preferably perpendicularly from upper sliding bracket member 306 in a generally cantilevered

orientation. Similarly, lower tire clamp 298 includes a lower sliding bracket member 310 extending between and slidably supported within channels 302, and a lower clamping jaw 312 extending preferably perpendicularly from lower sliding bracket member 310 in a generally cantilevered orientation. As described in more detail below, upper and lower clamping jaws 308, 312 each include restraining members, which in the illustrated embodiment are formed as multiple gripping rollers 314 (FIG. 33), enable a tire T clamped between clamping jaws 308, 312 to be positioned or moved within clamping jaws 308, 312 in a generally parallel orientation with jaws 308, 312, but restrain movement of the tire T about the rolling or central axis of the tire T such that the tire T is inhibited from rotating about that axis relative to a rim R clamped on mounting support 254.

100117] Referring now to FIG. 31 , tire holding assembly 256 is shown to include a drive motor 316 for moving upper sliding bracket member 306 within channels 302 and a drive motor 318 for moving lower sliding bracket member 310 within channels 302. Drive motors 316, 318 enable upper and lower tire clamps 296, 298 to be selectively and independently moved relative to each other in a vertically up and down direction.

(001181 In the illustrated embodiment, the control 16 of tire robot 30 or control 18 of mounting robot 40 is used to operate drive motors 316, 318 for positioning of upper and lower tire clamps 296, 298. Upon tire robot 30 positioning a tire T retained by tire end effector 190 into position between extended upper and lower tire clamps 296, 298, upper and lower clamps 296, 298 are caused to engage or clamp on tire T (FIG. 32). Tire end effector 190 then releases the tire T such that tire holding assembly 256 is fully retaining the tire T. Alternatively, however, movement of upper and lower tire clamps 296, 298 may be actuated by the system controller 12.

|OO119] Referring now to FIGS. 30, 32, and 33, and as previously noted, upper and lower clamping jaws 308, 312 include restraining members formed as multiple gripping rollers 314 that prevent rotation of the tire T about its central rolling axis relative to a rim R secured to mounting support 254. Gripping rollers 314, however, still allow movement of the tire T in a generally radial direction of tire T or longitudinal orientation relative to the upper and lower clamping jaws 308, 312. In the illustrated embodiment, as shown in FIG. 32, upper clamping jaw 308 includes six gripping rollers 314a and lower clamping jaw 312 includes five gripping rollers 314b.

|00120] FIG. 33 discloses that a gripping roller 314a of upper clamping jaw 308 includes a roller bearing 320, end caps 322, and a generally cylindrical, rigid outer member 324. Outer

member 234 includes annular projections formed as multiple ridges 326 extending circumferentially about cylindrical member 324. Roller bearing 320 extends between and is mounted to a frame 328 of upper clamping jaw 308 to enable rotation of outer member 324 about its longitudinal axis. In generally similar manner to the gripping roller 314a of upper clamping jaw 308, FIG. 33 discloses that a gripping roller 314b of lower clamping jaw 312 also includes a roller bearing 330, end caps 332, and a generally cylindrical outer member 334 having annular projections formed as multiple ridges 336 extending circumferentially thereabout. Roller bearing 330 extends between and is mounted to a frame 338 of lower clamping jaw 312 and enables rotation of outer member 334 about its longitudinal axis.

1001211 Ridges 326 of gripping roller 314a of upper clamping jaw 308 and ridges 336 of gripping roller 314b of lower clamping jaw 312 are adapted to engage the sidewalls of a tire T held between the clamping jaws 308, 312 when upper and lower tire clamps 296, 298 are caused to grasp the tire T. Ridges 326, 336 generally inhibit or restrain movement of the tire T along the axial direction of the outer members 324, 334. As such, a tire T clamped between upper and lower tire clamps 296, 298 is restrained from rotating about its rolling or central axis relative to a rim R clamped on mounting support 254. In the illustrated embodiment, outer members 324, 334 and ridges 326, 336 are formed of steel, such as ST37, and are formed from a steel rod or tube, such as with a lathe or screw machine, to the shape as shown.

|OO122] The circumferential orientation of annular ridges 326, 336 about the outer members

324, 334 and the ability of outer members 324, 334 to rotate about their longitudinal axis via roller bearings 322, 332, however, enables a tire T clamped between upper and lower tire clamps 296, 298 to move in a generally longitudinal orientation relative to the upper and lower clamping jaws 308, 312, which direction is generally perpendicular to the longitudinal axis of rotation of the outer members 324, 334 and is along a diameter or radius of the clamped tire.

100123) It is also within the scope of the invention to provide upper tire clamp 296 with the row of rollers 308 positioned at an angle either positive or negative relative to horizontal plane and the same for lower tire clamp 298 with the row of rollers 312 at an angle relative to horizontal plane. Such positioning of the rows of rollers on the tire clamps at an angle can be done in eight possible ways:

1) upper clamp rollers positive angle and lower clamp rollers positive angle

2) upper clamp rollers positive angle and lower clamp rollers negative angle

3) upper clamp rollers negative angle and lower clamp rollers positive angle

4) upper clamp rollers negative angle and lower clamp rollers negative angle

5) upper clamp rollers zero angle and lower clamp rollers positive angle

6) upper clamp rollers zero angle and lower clamp rollers negative angle

7) upper clamp rollers positive angle and lower'clamp rollers zero angle

8) upper clamp rollers negative angle and lower clamp rollers zero angle |OO124| As noted above, tire holding assembly 256 includes a tire pusher 304 (FIG. 34) mounted thereto, as shown in FIG. 26. Tire pusher 304 includes a bracket 340 to enable tire pusher 304 to be mounted to upper sliding bracket member 306 such that tire pusher 304 is able to move in combination with upper tire clamp 296. Tire pusher 304 further includes an extension cylinder 342 and two tire engaging arms 344. Arms 344 may alternately include ridges 345 on their surfaces, which ridges extend parallel to the central axis of each arm (FIG. 34). Ridges 345 create higher friction with tire T when the tire is engaged with arms 344 to prevent rotation of the tire around its center axis relative to rim R during mounting. Extension cylinder 342 is adapted to selectively extend and retract such that arms 344 may be caused to engage the tread area of a tire T clamped between upper and lower tire clamps 296, 298. Tire pusher 304, therefore, may be used to properly position and/or inhibit movement of the tire T while it is being mounted to a rim R in the manner discussed below. Tire T may be moved in the direction in which tire pusher 304 acts on tire due to the ability of roller grippers 314 of upper and lower tire clamps 296, 298 to rotate.

(00125J In the illustrated embodiment, restraining members of tire clamps 296, 298 are formed as gripping rollers 314 having annular projections formed as ridges 326, 336, with the gripping roller 314a of the upper clamping jaw 308 including four ridges 326 extending about the entire circumference of the outer member 324 and the gripping roller 314b of lower clamping jaw including three such ridges 336. It should be appreciated, however, that alternative restraining members and/or projections may be employed or arranged without affecting the scope of the present invention. For example, alternative ridges or structures may be used to engage tire sidewalls to prevent rotation of the tire about its rolling axis, such as spikes or studs positioned about the outer members in place of ridges and/or an alternative number of ridges may be positioned about the outer members. Further, the gripping rollers of upper and lower clamping members may be constructed to all have the same number and/or type of projections, or different projections. Still further, upper and lower tire clamps may be

constructed to include restraining members that do not allow the tire to rotate about its rolling axis and do not allow it to be positioned radially with respect to a clamped rim.

[00126] FIGS. 30A and 33A-33C illustrate alternative roller gripper arrangements that may be used with tire clamps 296, 298. As shown, the roller gripper 314b' of FIG. 33C includes only two annular ridges 336', with roller gripper 314b' being the outward or forward most roller gripper of the roller grippers of the lower tire clamp 298. The remaining roller grippers 314b" of lower tire clamp 298 each include three such annular ridges 336". The six upper roller grippers 314a' of the upper tire clamp 296 each include four annular ridges 326'. MOUNTING ROBOT AND MOUNTING TOOL END EFFECTOR

|OO127| Referring now to FIGS. 1 , 26 and 35-37, a mounting tool end effector 260 for use with mounting robot 40 described above is illustrated. Mounting tool end effector 260 is used in conjunction with mounting robot 40 upon securing of a rim R to mounting support 254 and the clamping of a tire T within tire clamps 296, 298 of tire holding assembly 256.

|OO128] Mounting tool end effector 260 includes two generally parallel arm members extending from a mounting plate 350, with one arm member constructed as a sidewall press member 346 and the other as a tire stretch member 348. Mounting plate 350 is adapted to be affixed to the mounting flange 156 of mounting robot 40, as described above. Sidewall press member 346 includes a shaft 352 and a press tool 354, with press tool 354 constructed as an arced member 356 having multiple rollers 358 that are used to engage the tire sidewalls in the manner described below. Tire stretch member 348 is of slightly shorter overall length relative to sidewall press member 346, with tire stretch member 348 including an angled tire bead stretcher 360. Depending on the features of the tire T and/or rim R to which the tire T is to be mounted, assembly may be accomplished in a single rotation or in two rotations.

|OO129) In a two rotation operation, tire clamps 296, 298 are initially used to lower a received tire T into position above a rim R secured by mounting support 254 such that the lower of the two tire sidewalls is positioned directly below the upward facing outer rim flange area of the rim R and positioned at the same relative height as, and in contact with, the rim drop center. Mounting tool end effector 260 is then moved by mounting robot 40 into the central opening or inner diameter of the tire T. The shaft 352 of sidewall press member 346 is used to engage and apply a radially outward force to the tire bead of the upwardly facing sidewall such that press tool 354 may engage the inner surface of the lower sidewall that is located adjacent the upward facing rim flange. Mounting robot 40 then causes press tool 354 to apply a downward force to the inner surface of the lower sidewall such that the lower tire bead,

which has previously been lubricated as described above, is forced over the upward facing rim flange. Mounting tool end effector 260 is then caused to make a rotation about the rim R with sidewall press member 346 leading the rotation whereby the lower facing tire bead is forced completely over the upward facing rim flange. Tire clamps 296, 298 may then be used to lower the tire T further such that the inner surface of the upper facing sidewall is positioned adjacent or in contact with the upper facing rim flange area of the secured rim R.

100130] Notably, mounting tool end effector 260 may initially contact tire T proximate upper and lower tire clamp 296, 298, with shaft 352 of sidewall press member 346 applying a force directed at the tire clamps 296, 298 (see FIG. 26). In such situation, tire pusher 304 may be used to apply a counterbalancing force to that of sidewall press member 346 such that tire T is prevented from moving longitudinally within tire clamps 296, 298.

1001311 Upon completion of the first rotation, tire lift 262 is used to apply an upward force to the portion of the tire T located opposite tire clamps 296, 298. This creates a radial gap between the upper facing tire bead and the upper facing rim flange 180 degrees opposite from the tire lift 262. Angled tire bead stretcher 360 of tire stretch member 348 may then be caused to engage the upper tire bead to pull the tire bead beyond the radius of the rim flange. Next, mounting robot 40 causes mounting tool end effector 260 to travel around rim R in the opposite direction from the first rotation such that angled tire bead stretcher 360 leads the sidewall press member 346. In this manner, angled tire bead stretcher 360 enables press tool 354 to force the previously lubricated upper tire bead past the upper facing rim flange.

|OO132| Alternately, instead of having two opposite rotations of mounting tool end effector

260, end effector 260 can be moved by robot 40 in its first rotation in the same direction as the second rotation described above. In such case tool 260 is programmed to be lifted or jump over the upper tire clamp 296 at the end of its first rotation to start the second rotation.

100133) A further alternative manner of mounting a tire T to a rim R is via a single rotation process. Such a process may, for example, be used on tires having sidewalls which may be compressed into proximity with each other by tire clamps 296, 298 such that a sidewall press tool may simultaneously force both previously lubricated tire beads beyond the upper rim flange in a single rotation about the retained rim.

(00134| Referring now to FIG. 37, mounting tool end effector 260 may be provided with sensors for evaluating the process of mounting a tire T to a rim R. For example, a first optical sensor 349 and a second optical sensor 347, both shown in phantom, may be used to measure distances to the tire sidewall during assembly with a comparison of the measured

values used to validate proper assembly. In the two rotation assembly operation discussed above, during the second rotation in which tire stretcher member 348 leads sidewall press member 346, first sensor 349 may be used to measure the distance to the tire sidewall bead at a location in advance of the tire bead stretcher 360. Correspondingly, second sensor 347 may be used to measure a distance to the tire sidewall bead at a location after passage of press tool 354. The difference between the measured distances may be used to evaluate proper mounting of the tire T to the rim R. For example, a difference of approximately one inch or more may indicate a correct mount process. In contrast, a difference considerably less than one inch may indicate an incorrectly mounted tire, such as may occur when the tire bead becomes positioned partially above press tool 354 thru the radial clearance between the press tool 354 and the rim upper edge during rotation of end effector 260. A transmission line, not shown, may be strung along mounting robot 40 to mounting robot controller 18 for processing of the optical sensor signals. Alternative sensors, such as triangulation sensors or the like, may be employed in place of optical sensors.

(OO135| Alternatively and/or additionally, load cells, such as load cells 351, 353 shown in phantom in FIG. 37, may be included on end effector 260 and/or current sensing devices may be included with mounting robot 40 for measuring and monitoring the six dimensional forces and moments applied to a tire T while being mounted to rim R. These measurements may be used to evaluate and adjust assembly parameters during the mounting operation. For example, high force and torque values may be compensated by adjusting the radial distances and angles of assembly during mounting. In addition, the measurements may be used to detect, for example, an incorrect tire and rim combination by evaluating excessive force when the tire inner diameter is too small for the rim outer diameter, or insufficient force when the tire inner diameter is too large for the rim outer diameter. In the illustrated embodiment, load cells 351, 353 are mounted within the tubular sidewall press member 346 and stretcher member 348 proximate mounting plate 350. A transmission line, not shown, may be strung along mounting robot 40 to mounting robot controller 18 for processing of the load cell signals.

|OO136] One or more current sensing devices may be installed within, or incorporated with, mounting robot controller 18 for monitoring and evaluating the current usage of the various axial motors of mounting robot 40. The measured current values of the robot 40 axis motors may be compared to a known or established or predicted current level that is based on, for example, the load and kinematics on robot 40. With the inclusion of such a feature, robot 40

may be programmed to stop when the measured current value exceeds the predetermined current limits, such as when an improperly matched tire and wheel are attempted to be assembled together or when the tire and wheel are not properly oriented relative to each other for assembly. In this manner, damage to tires, wheels, and the assembly equipment may be inhibited.

[00137] Referring again to FIG. 26, a calibration plate 362 is shown positioned on mounting support 254 with a mounting tool end effector 260 depicted in position adjacent the calibration plate 362 for explanatory purposes. Calibration plate 362 is used to program or teach mounting robot 40, such as a control 18 of mounting robot 40 and/or the system controller 12, the positional locations required for moving mounting tool end effector 260 about a rim R to assemble the tire T thereto. As illustrated, this programming or teaching may be accomplished via a pin 364 attached to and extending from mounting tool end effector 260 that may be selectively inserted into various holes 366 located about the periphery of calibration plate 362.

100138) Once tire T is mounted to rim R, rim R may be released from mounting support 254 by retracting movable clamping members 268. Rim robot 20 with rim end effector 160 may then be used to move the assembled wheel W to inflation apparatus 90.

1001391 As previously noted, the inclusion of restraining members on tire clamps prevents a tire that is clamped therebetween from rotating relative to the secured rim by resisting the rotational force imparted by press tool 354 . In certain applications this may be advantageous. For example, the assembly of tires to rims may involve a pre-balancing step involving the assembly of a tire to a wheel in a known relative orientation in order to provide balancing to the assembled wheel. For example, the tires and rims input into the system may include markings applied at earlier operations such as a sticker or grease pen marking applied to the tire and/or rim to indicate a centrifugal weight high point or low point. The markings on the tire and/or rim may then be used to coordinate the appropriate assembly orientation of the tire to the rim. With regard to the operation of the present assembly, a rim R may be placed on the mounting support 254 in a known orientation and the tire T supplied to the tire clamps 296, 298 in a known orientation. Subsequently, because the tire T is inhibited or prevented from rotating relative to the secured rim R, the tire T may be mounted to the rim R such that the assembly is appropriately aligned and pre-balanced.

|00i40| The correct orientation at which the rims R and/or tires T are to be supplied to the mounting assembly may be determined or established, for example, by detecting the

markings on the tires T and/or rims R by the tire vision system 120 and the rim vision system 115. This information may be input into the system controller 12, for example, and utilized by the tire and rim robots 30, 20 to correctly orient the rim R as it is placed on the mounting support by the rim robot 20 and/or correctly orient the tire T at it is supplied to the tire clamps 296, 298 by the tire robot 30. Alternatively, however, a rim vision system 115 may be constructed to detect the valve stem, which may be previously assembled to rim R before the present assembly operation.

1001411 It should be understood that pre-balancing may not be necessary or desired in every application. In such case, tire clamps need not include restraining members for preventing or inhibiting rotation of a clamped tire about its rolling axis.

OVERALL OPERATION AND METHOD

|OO142| As outlined above, the overall operation of tire and rim assembly apparatus or cell 10 involves receiving rims R and tires T into cell 10 by rim input conveyor 50 and tire input conveyor 60, respectively. Rim vision system 115 may be used to confirm the presence, relative orientation and/or position of the rim R at the end of rim input conveyor 50, and may also be used to determine certain characteristics or detect a marking or valve stem on the rim R. Tire vision system 120 is used to confirm the presence, relative orientation/and or position of a stacks of tires T ₅ as well as the uppermost tire T.

1001431 Rims R are selectively grasped by rim robot 20 using rim end effector 160. In the event it is desired to grasp the rim R from the opposite direction from that which is directed upwards, vertical lift table 110 may be used to elevate the rim R such that rim end effector 160 may be inserted from below rim R. Rim robot 20 then moves and positions the selected rim R at the lubrication station 70 where spray nozzles 230, 232 may be used to apply a lubrication solution to the tire bead flanges 252a, 252b of the rim R while the rim R is being rotated by robot 20 with rim end effector 160. After lubrication, the selected rim R is moved to the mounting assembly 80 and secured to the mounting supporting 254. Rim robot 20 may then return to rim input conveyor 50 to select the next rim R for selecting, moving, applying lubrication solution thereto, and moving to the other of the two mounting assemblies 80. Alternatively, prior to such selection of the next rim R, rim robot 20 and rim end effector 160 may be used to remove an assembled wheel assembly W from the other of the mounting tables 80 for movement to the inflation assembly 90.

[00144J Simultaneously with the selection of a rim R ₅ moving of the rim R, lubrication of the rim R, and clamping of the rim R, tire end effector 190 affixed to tire robot 30 may be used to

grasp and move a tire T as described above and outlined below. The upper most tire T of a stack S located adjacent tire vision system 120 maybe grasped with the tire end effector 190 upon determination of the tire T position by the vision system 120. Tire vision system 120 may then also be used to determine the rolling direction of the selected tire T. In the event that it is desired to reverse or flip the tire T, the tire T may be temporarily placed on turn table 130 such that the tire end effector 190 may grasp the tire T adjacent the other side.

|OO145| The selected tire T is then moved to the lubrication station 70 at which a lubrication solution is applied to the tire beads of the inner diameter via spray nozzles 230, 232 while the tire T is rotated by the tire robot 30. Subsequently, the tire T is moved to the mounting table 80 and clamped via a movable tire clamps 268a, 268b and fixed clamp 266. Tire clamps 296, 298, tire pusher 304, and tire lift 262 of mounting table 80 are used in conjunction with mounting tool end effector 260 and mounting robot 40 to coordinate assembly of the tire T to a previously lubricated and clamped rim R by aligning the tire T with the rim R, positioning the tire T adjacent the rim R, and moving the mounting tool end effector 260 about the rim R to force the tire beads over the upper facing rim flange. The assembled wheel W is subsequently re-grasped by the rim end effector 160 and moved by the rim robot 20 to the inflator assembly 90.

1001461 As indicated, rim robot 20, tire robot 30, and mounting robot 40 may be simultaneously operating or moving within the cell 10. Therefore, system control 12 may include a directing function whereby the position of each of the robots 20, 30, 40 is monitored to prevent the robots 20, 30, 40 from contacting each other. For example, a zone locking feature may be employed whereby, for example, tire robot 30 holding a tire T may be moved proximate to the lubrication station 70 and paused while rim robot 20 is being used to apply lubrication to a rim R.

(00147| As also indicated, alternative arrangements or constructions of robotic tire and rim assembly cells may be employed within the scope of the present invention. For example, as shown in FlG. 38, a robotic assembly cell 10' may include parallel tire and rim input conveyors 60', 50', respectively., that deliver tires and rims to rim and tire shuttles 406, 408, respectively. The illustrated cell 10', in like manner to cell 10 above, includes a tire robot 30', a rim robot 20', and a mounting robot 40', each with its respective robot control 16', 14', or 18', a lubrication apparatus 70', and two mounting assemblies 80a', 80b' and an associated system controller, such as a computer or PLC 12'. Each of these various stations are substantially similar to the robots, lubricating apparatus and mounting assemblies described

above for assembly cell 10. Assembled wheels are placed on wheel output conveyor 95' after assembly at mounting assemblies 80'.

[001481 It should also be appreciated that cells employing more or less than three robots, and/or more or less than two mounting assemblies, and/or more than one soaping station may be configured and still function as intended within the scope of the present invention. The number of robots, soaping stations, and mounting assemblies employed is dependent, at least in part, on the volume of wheel assemblies required to be produced by the cell. For example, an assembly cell could be configured to include a single robot with the robot adapted to grasp and move rims, tires, and assembled wheels using, for example, the end effector having four gripping posts described above. In such an embodiment, the robot may select a rim, move the selected rim to a single lubrication apparatus at a lubrication area, rotate the rim during lubrication, place the rim at a single mounting assembly, the robot may then select a- tire, move the selected tire to the lubrication apparatus, rotate the tire during lubrication, and place the tire at the mounting assembly. A mounting robot, or other mounting apparatus, may then be used to mount the tire to the wheel.

[OO149| Although rim robot 20 and rim end effector 160 are described above as being used to remove a mounted tire/rim assembly from a mounting assembly 80 for placement at a tire inflation assembly 90 or an output conveyor, it should be appreciated that alternative arrangements may be employed within the scope of the present invention. For example, tire robot 30 and tire end effector 190 may be used to remove the mounted tire/rim assembly from a mounting assembly 80. Alternatively, a separate robot may be used for removing mounted tire/rim assemblies from mounting assemblies, or a mounting robot may be constructed to both mount the tire to the rim and remove the mounted tire/rim assembly from a mounting assembly. In such case, the mounting robot may include both a tool end effector and another end effector or a modified end effector configured to enable both mounting and moving.

|00150] Additional equipment or operations may also be used in connection with the present invention. For example, rim input conveyor may include a valve insertion step or operation, as disclosed in United States Patent Nos. 6,481,083 and 6,886,231, both of which are assigned to the Burke E. Porter Machinery Co. of Grand Rapids, Michigan and are hereby incorporated herein by reference in their entireties. As previously noted, robotic tire and wheel rim assembly apparatus or cell 10 may include an inflator assembly or inflation apparatus 90. Such an inflator assembly may, for example, be constructed as disclosed in United States Patent Nos. 6, 502,618 and 6,176,288, or United States Reissue Patent No. Re.

39,312, all of which are also assigned to Burke E. Porter and are hereby incorporated by reference in their entireties. Still further, an alternative structure may be employed for assembling a tire to a rim, such as that disclosed in United States Patent No. 6,877,544 for a Robotic Apparatus and Method for Assembling a Tire to a Rim, which is also assigned to Burke E. Porter and hereby incorporated by reference in its entirety.

1001511 The tire and wheel rim assembly apparatus of the present invention provides significant benefits over prior known systems. The use of multi-axis robots speeds the automated selection, transfer, lubrication and mounting of both tires and wheel rims thereby reducing processing time and eliminating the need for cumbersome space and time consuming conventional conveyors within the lubrication and assembly area. The invention also allows the assembly of a wide variety of tires and wheel rims via flexible and adaptable multi-axis robots and associated end effectors, as well as enables systems to be configured using more or fewer robots, mounting assemblies, and lubrication apparatuses based on a required volume of wheels to be assembled. The present tire and wheel rim assembly apparatus also avoids the need for dedicated assembly equipment. Camera vision systems, or other automated detection methods, may be used to assure the provision of the correct tire with the correct wheel rim in the correct orientation for a desired rolling direction. Premarked and prebalanced tires and wheel rims can be aligned and assembled using the present invention in a manner preventing misalignment of the predetermined markings without the inclusion of time consuming and added alignment apparatus and processing. Further, specific processing times for lubricating both tires and wheel rims are reduced with the present invention as compared to prior known lubricating assemblies while the use of multiple robots and a pair of tire mounting stations maintains efficient and coordinated tire and wheel assembly, transfer to a subsequent inflator or balancing apparatus, if desired, and tire and wheel assembly on a continuous and uninterrupted basis.

|OO152| Changes and modification in the specifically described embodiments can be carried out without departing from the principles of the present invention which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law.