Field of the Invention

The present invention relates to manufacturing processes and systems utilised to produce mechanical seal components.

Background to the Invention

Traditionally, mechanical seal components are manufactured by a series of CNC manufacturing cells which process a raw material input of billet or bar stock into finished mechanical seal components by machining them to the correct dimensions in CNC lathes and mills, arranged in series along a manufacturing line. These machines must be fed with raw material manually, their production programmes must be manually selected and initiated, and once this has finished the part must be removed from the machine manually before being manually polished, washed and finally inspected for dimensional accuracy.

The current methods of manufacture and systems are disadvantaged in that they often lead to machine down-time, and inconsistent and reduced efficiency, process repeatability, and accuracy and quality of finished parts. This leads to increased costs in production of seals and use of natural resources.

It is desirable in the seal manufacturing industry for there to be a method and system for manufacturing which substantially mitigates machine down-time, and improves consistency and efficiency, process repeatability, and accuracy and quality of finished parts.

It is an object of the present invention to provide a method and system of manufacturing seals which addresses the above-mentioned problems and desires in the industry and reduces the cost of production of seals and use of natural resources. Statements of Invention

According to the present invention, there is provided apparatus for manufacturing at least two products which have different physical specifications, the apparatus comprising:

(A) a handling robot comprising means for holding one of a plurality of differing items of tooling and means for transferring said item to a manufacturing machine;

(B) means for changing said holding means to suit the tooling required for a particular product;

(C) a plurality of manufacturing machines

(i) each of which is capable of holding an item of tooling selected from a plurality of different items of tooling and

(ii) each of which is in operative communication with the handling robot;

(D) means for inspecting a workpiece placed in the vicinity of the handling robot and for feeding data relating to the physical characteristics of the workpiece to a controller robot to enable the handling robot to determine its suitability for the manufacture of at least one of said products; and

(E) a controller for holding data relating to the manufacturing steps for both of said products and configured to effect the manufacture of each of said products by determining the manufacturing machines to be used, the sequence of their operation and the tooling with which each is provided.

Preferably the holding means comprise a set of jaws, which may be jaws for gripping tooling.

The handling robot is preferably operable to provide each manufacturing machine with the required tooling at the required process stage and transfer material and parts between the plurality of manufacturing machines at the required process stage. The plurality of manufacturing machines may comprises at least two of a raw materials feed conveyor, a product forming machine, a washer, and a measuring machine.

The product forming machine may be a Computer Numeric Control, CNC, mill or lathe machine, for instance, a Computer Numeric Control (CNC) machine operable to machine a seal part in accordance with a prescribed tool path associated with a G- Code.

The measuring machine may a Coordinate Measuring Machine (CMM).

Preferably, the raw materials feed conveyor is operable to feed raw material required for production to the handling robot; the handling robot is operable to supply raw material to the product forming machine; the product forming machine is operable to form a mechanical seal product; the handling robot is operable to transfer the seal product from the product forming machine to the washer; the washer is operable to wash said seal product; and, the measuring machine is operable to measure the seal product relative to predefined dimensions and categorise each seal product as pass or fail relative to the predefined tolerances.

Preferably, the the handling robot and the plurality of manufacturing machines each comprise communicating means and communicate with each other to sequentially undertake the manufacturing process in real time.

The plurality of manufacturing machines may be disposed substantially circumferentially about the handling robot.

Preferably, means are provided to record the measurement of the seal product taken by the measuring machine and processing the recorded measurements in a Statistical Process Control (SPC) system.

The handling robot and manufacturing machines are advantageously connected to each other to communicate in real time. The handling robot and manufacturing machines may be controlled by a computer server.

The present invention also provides a process for manufacturing at least two products which have different physical specifications, the process comprising:

(A) providing a handling robot comprising means for holding one of a plurality of differing items of tooling and means for transferring said item to a manufacturing machine;

(B) the handling robot having means for changing said holding means to suit the tooling required for a particular product;

(C) providing a plurality of manufacturing machines;

(i) each of which is capable of holding an item of tooling selected from a plurality of different items of tooling; and

(ii) each of which is in operative communication with the handling robot;

(D) inspecting a workpiece placed in the vicinity of the handling robot and feeding data relating to the physical characteristics of the workpiece to a controller robot to enable the handling robot to determine its suitability for the manufacture of at least one of said products; and

(E) holding in a controller data relating to the manufacturing steps for both of said products and configured to effect the manufacture of each of said products by determining the manufacturing machines to be used, the sequence of their operation and the tooling with which each is provided.

Preferably, said holding means comprise a set of jaws.

Preferably, the handling robot provides each manufacturing machine with the required tooling at the required process stage and transfers material and parts between the plurality of manufacturing machines at the required process stage. Preferably, the plurality of manufacturing machines comprises at least two of a raw materials feed conveyor, a product forming machine, a washer, and a measuring machine.

The product forming machine may a Computer Numeric Control, CNC, mill or lathe machine.

The measuring machine may be a Coordinate Measuring Machine (CMM).

In a preferred process, the raw materials feed conveyor feeds raw material required for production to the handling robot; the handling robot supplies raw material to the product forming machine; the product forming machine forms a mechanical seal product; the handling robot transfers the seal product from the product forming machine to the washer; the washer washes said seal product; and, the measuring machine measures the seal product relative to predefined dimensions and categorises each seal product as pass or fail relative to the predefined tolerances.

The product forming machine may be a Computer Numeric Control, CNC, machine operable to machine a seal part in accordance with a prescribed tool path associated with a G-Code.

The handling robot and the plurality of manufacturing machines may each comprise communicating means which communicate with each other to sequentially undertake the manufacturing process in real time.

The handling robot and manufacturing machines may be connected to each other in a mesh communication network.

The handling robot and manufacturing machines may be controlled by a computer server.

The plurality of manufacturing machines may be disposed substantially circumferentially about the handling robot. The present invention further provides a computer program product comprising a non- transitory readable medium holding computer program instructions, the computer program comprising instructions executed by a hardware processor to carry out the process of the invention.

The present invention also provides mechanical seal manufacturing process comprising: providing a handling robot, the handling robot suitably disposed to interact with a plurality of at least manufacturing machines wherein the robot is operable to provide each manufacturing machine with the required tooling at the required process stage and transfer material and parts between the plurality of manufacturing machines at the required process stage.

Furthermore, the present invention provides apparatus for manufacturing batches of at least two products which have different physical specifications, the apparatus comprising a robotic cell comprising a handling robot and one or more CNC manufacturing cells, wherein the robot is configured to fit and removes the machine part holding jaws with no human intervention and to provide the required tooling which varies for each batch, said robot being further configured automatically to replace worn or broken tooling, to measure and deburr, and to wash and inspect each product, thereby providing an end to end robotically driven complete manufacturing cycle with no human intervention. Such an arrangement enables small batch production of products in of low volumes with varying specifications..

Brief Description of the Drawings

The accompanying drawings are as follows:

Figure 1 is a flow chart depicting the mechanical seal manufacturing process according to the present invention; and

Figure 2 is a schematic drawing of a mechanical seal manufacturing system according to the present invention. Detailed Description of the Invention

The inventive process will now be described, by way of example only, with reference to the accompanying drawings.

Referring to Fig. 1 and Fig. 2 of the accompanying drawings, a mechanical seal manufacturing process and system, according to the present invention, comprises a robot handler (10) and a plurality of manufacturing machines (12) circumferentially disposed about the robot handler (10). The plurality of manufacturing machines includes a raw materials feed conveyor, a product forming machine, a washer, and a measuring machine.

The loading robot (10) has a range of jaws and tooling in which to functionally engage with material and parts to coordinate movement of material and parts to and between the plurality of manufacturing machines. The product forming machine is a Computer Numeric Control, CNC, mill or lathe machine. The measuring machine is a Coordinate Measuring Machine, CMM.

In use, the system may operate such that, for example: the raw materials feed conveyor is operable to feed raw material required for production to the handling robot. The handling robot is operable to supply raw material to the product forming machine. The product forming machine is operable to form a seal product. The handling robot is operable to transfer the seal product from the product forming machine to the washer. The washer is operable to wash said seal product. The measuring machine is operable to measure the seal product relative to predefined dimensions and categorise each seal product as pass or fail relative to the predefined tolerances.

The robot (10) and plurality of manufacturing machines (12) have communication means such that the robot (10) communicates pre-determined processing programmes and pathways to the plurality of manufacturing machines and data is fed back to the robot during the mechanical seal manufacturing process, in real time.

Referring particularly to Figure 1 , the mechanical seal manufacturing process begins with determining which seal product is to be produced (110). This step comprises selecting a predefined seal product from a range of seal products and loading the manufacturing process program associated therewith. At a first decision gate (112) it is determined whether or not the tooling and/or the jaws on the product forming Computer Numeric Control, CNC, mill or lathe machine need replacing to accommodate the seal product which is to be produced. If the decision at this stage is that the tooling and/or jaws are to be replaced, a robotic arm, of the loading robot (10), removes the existing tool/jaws from the CNC product forming machine (114). The loading robot (10) then identifies the correct storage location for removed tooling/jaws using an associated identification, ID, microchip (116) and stores the removed tooling/jaws (118). The robot (10) then identifies the required tooling/jaws using an associated identification, ID, microchip (120) and installs the required tooling/jaws onto the CNC product forming machine (122).

At a second decision gate (124), the process checks whether or not the tooling/jaw change has been completed, and, if so, allows the next stage in the process to be initiated (124). The appropriate raw material is then identified and picked up from the raw material feed conveyor (126) and placed into the jaws of the CNC product forming machine in advance of the machining commencing (128).

The CNC product forming machine then processes the raw material into the seal product (130). In-cycle measurement of the seal product can be undertaken on the CNC product forming machine (132) and a determination on whether the measurements of the seal product in-cycle comply with predetermined measurements (134).

Once the machining process of the seal product has been completed, the seal product is part de-burred on the CNC product forming machine (136) and inspected on the machine. The robotic then removes the seal product from the CNC product forming machine (138) and the seal product is again part de-burred, this time externally of the machine (140).

The robot (10) then picks up the seal product and places it into the washer (142) before drying it and placing it onto the CMM measuring machine (144). The CMM measuring machine conducts a dimensional inspection of the seal product (146). The results of the dimensional inspection are compared to pre-defined dimensions for the seal product (148) and categorized into pass or fail, or more preferably pass (150), fail (152) or re-work (154). If the part is able to be reworked (8), then it can be placed back onto either this, or another, CNC product forming machine to have more material removed to bring it into the required tolerance band. Each of the categorized pass, fail and re-work (150), (152) and (154) seal products picked are removed from the CMM measuring machine (156), (158) and (160), respectively. The pass seal products are placed in a pass bin (162). The fail seal products are placed in a fail bin (164). The re-work seal products are placed in a re-work bin (166) and then subsequently transferred back into the process for re-working using the CNC product forming machine in step (128) The results of the CMM measuring machine inspection (146)/( 148) are utilised to monitor the process statistically in, for example, a Statistical Process Control, SPC, system (168).

The operation of the apparatus in accordance with the present invention will now be described in greater detail, by way of example only, in connection with the production of mechanical seals which differ in their specification, such as in their sizes and/or their shapes or some other physical characteristics. The products are referred to as variants and the apparatus as the cell. Two manufacturing machines, M1 and M2, are used in this operation.

A) Cell start-up with new variant

(1 ) The operator loads new sub-spindle jaws if necessary

(2) The robot picks a jaw gripper from the tool stand (if necessary)

(3) The robot unload/load new sub-spindle jaws in to jaw stand

(4) The operator loads a new barcode on to an infeed belt

(5) The operator loads raw material after the barcode onto the infeed belt

(6) The new barcode is scanned

(7) The new variant is registered and cell run out/emptying commenced (8) Once the cell is empty of previous components the new variant details are loaded (under control of the software)

(9) Machine 1 (M1 ) o The robot picks a jaw gripper from tool stand (if necessary) o The robot picks correct jaws from jaw stand o The robot verifies jaw selection via use of RFID scanner o The robot air knife used on spindles o The robot unloads/loads jaws in the M1 sub-spindle/main spindle o The robot verifies old jaw type using RFID scanner o The robot drops off old jaws in jaw stand

(10) Machine 2 (M2) o The robot picks the correct jaws from jaw stand o The robot verifies jaw selection via use of RFID scanner o The robot air knife used on spindles o The robot unloads/loads jaws in M2 sub-spindle/ main spindle o The robot verifies old jaw type using RFID scanner o The robot drops off old jaws in jaw stand o The robot gripper is exchanged to part gripper

(11 ) Machine 1 o The robot picks the raw component from infeed conveyor o The robot re-grips component for height accuracy o The robot loads the M1 main spindle o The robot starts M1 machining (12) Machine 2 o The robot picks raw component from infeed conveyor o The robot re-grips component for height accuracy o The robot loads M2 main spindle o The robot starts M2 machining

(13) Machine 1 o The robot picks finished component from M1 sub-spindle o The robot air knife is used on spindles o The robot uses blow off box for cleaning excess coolant/chips o The robot deburrs/brushes the part o The robot washes the part o The robot blows off for residue/cool down function o The robot re-grips for component height accuracy (may not be required at this stage) o The robot loads CMM and starts o Feedback is awaited from M1 as to whether part good or bad o The robot picks finished component from CMM

■ If the part is good, the robot loads the part on to outfeed conveyor and proceeds to M2

■ If the part is bad, the robot drops the part into scrap-chute and repeats raw material load/machining/unload/measurement process for M1. This is done 3-off times before M1 is deemed out of tolerance and deactivated from system (14) Machine 2 o The robot picks finished component from M2 sub-spindle o The robot air knife is used on the spindles o The robot uses blow off box for cleaning excess coolant/chips o The robot deburrs/brushes the part o The robot washes the part o The robot blow off for residue/cool down function o The robot re-grips for component height accuracy (may not be required at this stage) o The robot loads the CMM and starts o Feedback is awaited from M2 as to whether part good or bad o Robot picks finished component from CMM

■ If the part good, the robot loads part on to the outfeed conveyor

■ If the part is bad, the robot drops part into thescrap-chute and repeats raw material load/machining/measurement process. This is done 3-off times before M2 is deemed out of tolerance and deactivated from system

If both M1 and M2 are now within tolerance, full cycle commences.

B) Full cycle with new variant

(15) Machine 1 o The robot picks raw component from infeed conveyor o The robot re-grips the component for height accuracy o The robot loads M1 main spindle o The robot starts M1 machining

After half machine cycle time the robot commences process with M2 to stagger total cell process output (16) Machine 2 o The robot picks raw component from infeed conveyor o The robot re-grips component for height accuracy o The robot loads M2 main spindle o The robot starts M2 machining

(17) Machine 1 o The robot picks finished component from the M1 sub-spindle o The robot air knife used on the spindles o The robot uses blow off box for cleaning excess coolant/chips o The robot deburrs/brushes the part o The robot washes part o The robot blow off for resid ue/cool down function o The robot re-grips for component height accuracy (may not be required at this stage) o Depending on the cycle initial settings, eg 1 in 5 parts measured, the robot loads CMM starts measuring otherwise offloads part on outfeed conveyor o If CMM, the robot waits feedback from M1 as to whether part good or bad o The robot picks finished component from CMM

■ If part is good, the robot offloads part on to outfeed conveyor

■ If part is bad, the robot drops part into scrap-chute

(18) Machine 2 o The robot picks finished component from the M2 sub-spindle o The robot air knife is used on spindles o The robot uses blow off box for cleaning excess coolant/chips o The robot deburrs/brushes the part o The robot washes the part o The robot blow off for residue/cool down function o The robot re-grips for component height accuracy (may not be required at this stage) o Depending on cycle initial settings, eg 1 in 5 parts measured, the robot loads CMM starts measuring otherwise offloads part on outfeed conveyor o If CMM, the robot waits feedback from M2 as to whether part good or bad o The obot picks finished component from CMM

■ If the part is good, the robot offload’s the part on to the outfeed conveyor

■ If part is bad, the robot drops part into scrap-chute.

The process of loading raw components in machines is repeated until batch requirement complete/new variant loaded.