Wheelhouse robotic roller hemming

Abstract

A robotic roller hemming apparatus includes a mounting member having a face for operative connection of the mounting member to a multi-axis controllable robotic arm, and a bracket extending from the face. A tracking roller is mounted on the bracket. A slide plate is operatively connected to the bracket and slidable relative to the bracket. A hemming roller is operatively connected to the slide plate proximate the tracking roller for roller hemming nested metal panels therebetween the hemming and tracking rollers. A slide actuator connects the bracket and the slide plate for moving the hemming roller toward and away from the tracking roller.

1 . A robotic roller hemming apparatus comprising:
 a mounting member including face for operative connection of the mounting member to a multi-axis controllable robotic arm, and a bracket extending from said face;   a tracking roller mounted on said bracket;   a slide plate operatively connected to said bracket and slidable relative to said bracket;   a hemming roller operatively connected to said slide plate proximate said tracking roller for roller hemming nested metal panels therebetween said hemming and tracking rollers; and   a slide actuator connecting said bracket and said slide plate for moving said hemming roller toward and away from said tracking roller.   
   
   
       2 . The robotic roller hemming apparatus of  claim 1 , including a linkage assembly operatively connected to said mounting member and said hemming roller for pivoting said hemming roller relative to said mounting member; and
 a pivot actuator for actuating said linkage assembly to pivot said hemming roller.   
   
   
       3 . The robotic roller hemming apparatus of  claim 2 , wherein said linkage assembly includes:
 a pivot bar having first and second opposite ends, said pivot bar first end being pivotally connected to said slide plate and said pivot bar second end being operatively connected to said hemming roller;   a link bar having first and second opposite ends, said link bar first end being pivotally attached to said pivot bar second end adjacent said hemming roller; and   a bell crank arm having first and second opposite ends, said bell crank arm first end being pivotally connected to said link bar second end and said bell crank arm second end being pivotally connected to said pivot actuator;   said bell crank arm being pivotally connected to said slide plate intermediate said bell crank arm first and second ends.   
   
   
       4 . The robotic roller hemming apparatus of  claim 3 , including a stop mounted to said slide plate, said stop limiting the pivotal movement of said pivot bar. 
   
   
       5 . The robotic roller hemming apparatus of  claim 2 , wherein said pivot actuator is mounted on said slide plate. 
   
   
       6 . The robotic roller hemming apparatus of  claim 1 , wherein said slide actuator is mounted on said mounting member bracket. 
   
   
       7 . The robotic roller hemming apparatus of  claim 1 , wherein said mounting member bracket includes a linear track, and said slide plate is operatively engaged with said linear track and slidable along said linear track. 
   
   
       8 . The robotic roller hemming apparatus of  claim 7 , wherein said linear track includes a pair of rails, and said slide plate includes a pair of bearing blocks engaged with said pair of rails. 
   
   
       9 . A robotic roller hemming system comprising:
 a first multi-axis controllable robotic arm having an end effecter that carries a hemming anvil;   a second multi-axis controllable robotic arm having a roller hemming head at an end thereof, said roller hemming head including a tracking roller and a multi-positional hemming roller capable of performing both pre-hemming and final hemming operations;   said hemming roller being adjustable between pre-hemming and final hemming positions and cooperable with said tracking roller and anvil to pre-hem and final hem a workpiece;   wherein said hemming roller performs pre-hemming and subsequent final hemming of said workpiece sequentially along a single hemming path.   
   
   
       10 . The robotic roller hemming system of  claim 9 , wherein said hemming roller is positionable about an edge of said workpiece on one side of the workpiece; and
 said anvil is positionable adjacent the workpiece about a side opposite said hemming roller.   
   
   
       11 . The robotic roller hemming system of  claim 9 , wherein said first robotic arm end effecter comprises a robotic tool exchange unit for interchanging said anvil with at least one alternative anvil. 
   
   
       12 . The robotic roller hemming system of  claim 11 , including an anvil storage unit for holding said at least one alternative hemming anvil. 
   
   
       13 . The robotic roller hemming system of  claim 9 , wherein said anvil includes an attachment device for temporary attachment of said anvil to said workpiece. 
   
   
       14 . The robotic roller hemming system of  claim 13 , wherein said attachment device includes an arrangement of vacuum cups. 
   
   
       15 . The robotic roller hemming system of  claim 9 , wherein said first robotic arm includes a location unit for positioning said anvil relative to a workpiece. 
   
   
       16 . The robotic roller hemming system of  claim 9 , wherein said hemming roller includes an indexing feature cooperable with an edge of said anvil that allows for indexing of said hemming roller between pre-hemming and final hemming positions. 
   
   
       17 . The robotic roller hemming system of  claim 9 , wherein said roller hemming head includes a servo positioner for adjusting the hemming roller between various pre-hemming and final hemming angular positions relative to said anvil. 
   
   
       18 . The robotic roller hemming system of  claim 9 , wherein said roller hemming head includes an actuator for adjusting the hemming roller between various pre-hemming and final hemming angular positions relative to said anvil. 
   
   
       19 . The robotic roller hemming system of  claim 9 , wherein said tracking roller is engagable with said anvil to aide in guiding said roller hemming head along said anvil. 
   
   
       20 . The robotic roller hemming system of  claim 9 , wherein said roller hemming head includes a slide unit for compressing said workpiece and said anvil between said hemming roller and said tracking roller. 
   
   
       21 . The robotic roller hemming system of  claim 20 , wherein said slide unit linearly moves said hemming roller to adjust the distance between said hemming roller and said tracking roller. 
   
   
       22 . A method for robotic roller hemming comprising the steps of:
 providing a first multi-axis controllable robotic arm having an end effecter that carries a hemming anvil having a hemming surface and a tracking surface;   providing a second multi-axis controllable robotic arm having a roller hemming head at an end thereof, said roller hemming head including a hemming roller adjustable between pre-hemming and final hemming positions and a tracking roller proximate said hemming roller;   employing said first robotic arm to position said anvil hemming surface adjacent a workpiece;   adjusting said hemming roller to said pre-hemming position;   employing said second robotic arm to position said roller hemming head relative to said workpiece and said anvil such that said tracking roller contacts said anvil tracking surface and said hemming roller engages said workpiece;   employing said second robotic arm to move said roller hemming head along said anvil such that said tracking roller follows said anvil tracking surface and said hemming roller pre-hems said workpiece;   adjusting said hemming roller to said final hemming position; and   employing said second robotic arm to move said roller hemming head along said anvil such that said tracking roller follows said anvil tracking surface and said hemming roller final hems said workpiece.   
   
   
       23 . The method of  claim 22 , wherein a path followed by said hemming roller during pre-hemming is also followed by said hemming roller during final hemming. 
   
   
       24 . The method of  claim 23 , wherein during final hemming, said hemming roller follows said path in the same direction of travel as during pre-hemming. 
   
   
       25 . The method of  claim 23 , wherein during final hemming, said hemming roller follows said path in a reverse direction relative to a direction of travel followed during pre-hemming. 
   
   
       26 . The method of  claim 22 , further including the step of:
 after said first robotic arm positions said anvil hemming surface adjacent said workpiece, temporarily attaching said anvil to said workpiece to stabilize said anvil relative to said workpiece.   
   
   
       27 . The method of  claim 22 , wherein said roller hemming head includes a slide unit for engaging and disengaging said tracking roller with said anvil tracking surface and said hemming roller with said workpiece;
 the method further including the steps of actuating said slide unit to engage said tracking roller with said anvil tracking surface and said hemming roller with said workpiece prior to pre-hemming; and   actuating said slide unit to disengage said tracking roller with said anvil tracking surface and said hemming roller with said workpiece after final hemming.   
   
   
       28 . The method of  claim 22 , further comprising the steps of:
 after said hemming roller final hems said workpiece, employing said second robotic arm to move said roller hemming head away from said workpiece; and   employing said first robotic arm to move said anvil away from said workpiece.