Integrated, automated, variable sheet metal forming and assembly system

Abstract

An integrated, automated, variable sheet metal forming and assembly system includes a plurality of robotic material conveyors and a forming subsystem including at least one sheet metal draw press apparatus. An assembly subsystem is in series with and downstream from the forming subsystem. The assembly subsystem includes a roller hemming apparatus. An inspection subsystem is in series with and downstream from the assembly subsystem. The plurality of robotic material conveyors are operable to convey assembly workpieces to and from the subsystems.

1 . An integrated, automated, variable sheet metal forming and assembly system comprising:
 a plurality of robotic material conveyors;   a forming subsystem including at least one sheet metal draw press apparatus;   an assembly subsystem in series with and downstream from said forming subsystem, said assembly subsystem including a roller hemming apparatus; and   an inspection subsystem in series with and downstream from said assembly subsystem;   said plurality of robotic material conveyors being operable to convey assembly workpieces to and from said subsystems.   
   
   
       2 . The integrated system of  claim 1 , wherein said forming subsystem includes at least one electromagnetic pulse apparatus in series with and downstream from said sheet metal draw press apparatus. 
   
   
       3 . The integrated system of  claim 2 , including two electromagnetic pulse apparatuses in parallel with each other. 
   
   
       4 . The integrated system of  claim 1 , wherein said forming subsystem includes a laser trim apparatus in series with and downstream from said sheet metal draw press apparatus. 
   
   
       5 . The integrated system of  claim 1 , wherein said forming subsystem includes a roller hemming apparatus in series with and downstream from said sheet metal draw press apparatus. 
   
   
       6 . The integrated system of  claim 1 , wherein said forming subsystem includes at least one die changer for changing dies of the draw press apparatus. 
   
   
       7 . The integrated system of  claim 6 , wherein said forming subsystem includes two die changers and a plurality of die sets having a plurality of individual die, said individual die of each die set being divided amongst said two die changers. 
   
   
       8 . The integrated system of  claim 1 , wherein said forming subsystem includes at least one scrap conveyor adjacent said draw press apparatus for conveying scrap metal pieces away from said forming subsystem. 
   
   
       9 . The integrated system of  claim 1 , wherein said inspection subsystem includes a white light inspection apparatus. 
   
   
       10 . The integrated system of  claim 1 , wherein said roller hemming apparatus of said assembly subsystem includes a plurality of interchangeable anvils. 
   
   
       11 . A method for integrated sheet metal forming and assembly, the method comprising:
 providing a plurality of robotic material conveyors for conveying sheet metal workpieces;   introducing a sheet metal blank to a forming subsystem including a sheet metal draw press apparatus to form a sheet metal panel;   conveying said sheet metal panel to an assembly subsystem including a roller hemming apparatus;   assembling a plurality of sheet metal panels in said assembly subsystem by using said roller hemming apparatus to form a hemmed sheet metal assembly; and   conveying said sheet metal assembly to an inspection system for robotic inspection of said sheet metal assembly.   
   
   
       12 . The method of  claim 11 , including the steps of:
 prior to conveying said sheet metal panel to said assembly subsystem, conveying said sheet metal panel to an electromagnetic pulse apparatus; and   performing at least one of a trim operation, a re-strike operation, a flange operation, and a pierce operation on said sheet metal panel using said electromagnetic pulse apparatus.   
   
   
       13 . The method of  claim 11 , including the steps of:
 prior to conveying said sheet metal panel to said assembly subsystem, conveying said sheet metal panel to a laser trim apparatus; and   performing robotic laser trimming of said sheet metal panel using said laser trim apparatus.   
   
   
       14 . The method of  claim 11 , including the steps of:
 prior to conveying said sheet metal panel to said assembly subsystem, conveying said sheet metal panel to a roller hemming apparatus; and   performing a hemming operation on said sheet metal panel using said roller hemming apparatus.   
   
   
       15 . The method of  claim 11 , including the steps of:
 providing a plurality of die changers in said forming subsystem for changing dies of said draw press apparatus;   providing a plurality of die sets including a plurality of individual die; and   dividing said individual die of each die set amongst said plurality of die changers.