Vehicle framing system for plurality of vehicle body styles

• US 20050236461A1
• Filed: 06/23/2005
• Published: 10/27/2005
• Est. Priority Date: 04/08/2002
• Status: Active Grant

• Current Assignee: Comau LLC (Stellantis NV)
• Original Assignee: Progressive Tool & Industries, Co.
• Inventors: Kilibarda, Velibor, Zanger, Leonard A.
• Granted Patent: US 7,510,109 B2
• Time in Patent Office: Days
• US Class Current: 228/101
• CPC Class Codes: B23K 2101/006 Vehicles
• CPC Class Codes: B23K 37/047 moving work to adjust its position between soldering, welding or cutting steps B23K37/053 takes precedence
• CPC Class Codes: B23Q 7/02 by means of drums or rotating tables or discs
• CPC Class Codes: B62D 65/02 Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making

Abstract

An apparatus and method for randomly interchanging up to four pairs of side framing gates at a framing station of a vehicle assembly line while maintaining a predetermined build cycle time interval of the assembly line. The system employs first and second carousels positioned on opposite sides of the assembly line upstream of the framing station and third and fourth carousels positioned on opposite sides of the production line downstream of the framing station. The system further includes a first linear track structure extending from the first carousel to a first side of the framing station, a second linear track structure extending from the second carousel to a second, opposite side of the framing station, a third linear track structure extending from the third carousel to the first side of the framing station, a third linear track structure extending from the third carousel to the first side of the framing station, and a fourth linear track structure extending from the fourth carousel to the second side of the framing station. The carousel includes at least two sides, possibly three sides, four sides or more, each side capable of receiving a framing gate. The framing gates positioned at the framing station are randomly interchanged by a combination of rotary movements of the carousels and linear movements of framing gates along the linear track structures.

Claims

1. A method of moving pairs of framing gates to a framing station on a motor vehicle assembly line where loosely preassembled vehicle bodies are clamped by the framing gate pairs while the bodies are welded to form a rigid vehicle body, the method comprising the steps of:

providing a pair of carousels each having a plurality of substantially flat sides;

positioning the carousels along and on opposite sides of the assembly line in spaced relation to the framing station;

mounting the carousels for rotation to bring successive sides of the carousel into a discharge position proximate and substantially parallel to the assembly line;

positioning a pair of framing gates on one side of the respective pair of carousels;

rotating the carousels to bring the one carousel sides into the discharge position;

discharging the framing gates from the carousels; and

sliding the framing gates along the assembly line to opposite sides of the framing station.

2. The method of claim 1 further comprising the step of:

providing linear track structures extending from each carousel to the framing station; and

wherein the sliding step of the discharged framing gates along the assembly line to the framing station includes sliding the discharged framing gates along the linear track structures to the framing station.

3. The method of claim 1, wherein the rotating step of the carousels further comprises:

generating an air cushion between an underface of the carousels and a support surface to lift the carousels off of the support surface; and

thereafter applying a turning force to the lifted carousels.

4. The method of claim 1, wherein the pair of carousels includes a first pair of carousels positioned upstream on the assembly line from the framing station, and the pair of framing gates includes a first pair of framing gates, and wherein the sliding step of the discharged framing gates along the assembly line to opposite sides of the framing station includes sliding the framing gates downstream to the framing station, and further comprising the steps of:

providing a second pair of carousels each having a plurality of substantially flat sides;

positioning the second pair of carousels along and on opposite sides on the assembly line downstream of the framing station;

mounting the second pair of carousels for rotation to bring successive sides of the second pair of carousels into a discharge position proximate and substantially parallel to the assembly line;

positioning a second pair of framing gates on one side of the respective second pair of carousels;

rotating the second pair of carousels to bring the one sides of the second pair of carousels into the discharge position;

discharging the second pair of framing gates from the second pair of carousels; and

sliding the discharged second pair of framing gates upstream to the framing station.

5. The method of claim 4 further comprising the steps of:

providing a third pair of framing gates;

positioning the third pair of framing gates on a second side of one of said first and second pairs of carousel; and

discharging the third pair of framing gates from the second side of the respective carousels for delivery to the framing station.

6. The method of claim 5 further comprising the steps of:

providing a fourth pair of framing gates;

positioning the fourth pair of framing gates on opposite sides of the framing station;

randomly interchanging the pair of framing gates positioned at the framing station by selective rotation of the carousels; and

selective sliding movement of the framing gates between the framing station and the carousels.

7. A method of body framing on a vehicle assembly line in which loosely pre-assembled vehicle bodies are moved incrementally along a single assembly line from station to station, successive loosely pre-assembled vehicle bodies arrive at a framing station along the assembly line at predetermined build cycle time intervals, and each loosely pre-assembled vehicle body arriving at the framing station is welded to form a rigid vehicle body, the method for body framing comprising the steps of:

positioning a plurality of more than three pairs of opposed side framing gates at opposite sides of the framing station for use in welding a respective plurality of more than three vehicle body styles allowing random production of the plurality of more than three vehicle body styles on the single assembly line; and

randomly exchanging with a transfer apparatus assembly any of the plurality of pairs of side framing gates positioned at the framing station with any other of the plurality of pairs of side framing gates within the predetermined build cycle time interval to allow the random production interchange of the more than three vehicle body styles on the single assembly line while maintaining the predetermined build cycle time interval.

8. The method of claim 7, wherein the randomly exchanging step with the transfer apparatus assembly includes the step of coacting a rotary transfer apparatus with a linear transfer apparatus.

9. The method of claim 8, further comprising the step of delivering framing gates with the rotary transfer apparatus to the linear transfer apparatus for delivery to the framing station.

10. The method of claim 9, further comprising the step of positioning first and second carousels on the rotary transfer apparatus of on opposite sides of the assembly line upstream of the framing station and positioning third and fourth carousels on the rotary transfer apparatus on opposite sides of the assembly line downstream of the framing station.

11. The method of claim 10, providing a first linear track system of the linear transfer apparatus extending from the first carousel to a first side of the framing station, providing a second linear track structure of the linear transfer apparatus extending from the second carousel to a second, opposite side of the framing station, providing a third linear track structure of the linear transfer apparatus extending from the third carousel to the first side of the framing station, and providing a fourth linear track structure of the linear transfer apparatus extending from the fourth carousel to the second side of the framing station.

12. The method of claim 11, further comprising the step of selectively receiving a framing gate on at least one side of at least one of the first, second, third, and fourth carousels, each carousel having a polygonal configuration including at least two sides, each side capable of receiving a framing gate.

13. The method of claim 12, further comprising the steps of providing the plurality of more than three pairs of opposed side framing gates to include four pairs of framing gates, and providing each carousel with three sides, positioning the first pair of framing gates on opposite sides of the framing station, positioning the second pair of framing gates on respective first sides of the first and second carousels, positioning the third pair of framing gates on respective second sides of the first and second carousels, and positioning the fourth pair of framing gates on respective first sides of the third and fourth carousels, randomly interchanging all of the pairs of framing gates by at least one of linear gate movements along the linear track structures and a combination of rotary movements of the carousels and linear gate movements along the linear track structures.

14. The method of claim 11 further comprising the steps of:

providing a base structure;

providing a first pair of spaced pillars mounted on the base structure on the first side of the framing station; and

providing a second pair of spaced pillars mounted on the base structure on the second side of the framing station];

moving the first and second pairs of pillars on the base structure between outboard positions spaced outwardly from the assembly line and inboard positions proximate the assembly line, the first pair of pillars in its outboard position linearly aligned with the first and third linear track structures, and the second pair of pillars in its outboard position linearly aligned with the second and fourth linear track structures;

delivering the framing gates to the respective pillar pairs along the respective linear track structures with the pillar pairs in the outboard positions];

thereafter moving the pillar pairs to the inboard positions to position the framing gates proximate the assembly line for clampingly engaging loosely preassembled vehicle bodies preparatory to welding operations.

15. A method for use in delivering framing gates to a framing station on a vehicle body assembly line, the carousel comprising the steps of:

providing a base structure positioned proximate the assembly line and including a support surface and a central pivot shaft upstanding from the support surface;

providing a carousel body supported on the support surface, mounted on the pivot shaft for rotary movement about the axis of the shaft, and defining a plurality of sides, each side adapted to receive a framing gate;

generating an air cushion between the support surface and an underface of the carousel body to lift the carousel body off of the support surface; and

applying a turning force to the carousel body to rotate the body about the central axis to bring successive sides of the body into a position proximate the assembly line.

16. The method of claim 15, wherein the air cushion generating step further comprises the step of providing a plurality of air bags positioned on the underface of the carousel body and each air bag including a plurality of apertures in confronting relation to the support surface allowing pressurized air delivered to the air bags to inflate the bags to raise the carousel body off of the support surface and air escaping from the air bags through the apertures to generate an air cushion between the air bags and the support surface.

17. The method of claim 16, wherein the air cushion generating step further comprises the step of providing air bags positioned in circumferentially spaced relation about the central axis of the pivot shaft.

18. The method of claim 16 intended for use with a linear track structure having one end positioned proximate the framing station and a free end, and further comprising the step of:

supporting a respective framing gate on a carousel track structure located on each side of the carousel body and configured to be aligned with the free end of the linear track structure as the respective side of the carousel body is moved into a position proximate the assembly line allowing the framing gate to be slid off the carousel track structure and onto the linear track structure for delivery to the framing station.

19. A method for use in delivering framing gates to a framing station on a vehicle body assembly line, the method comprising the steps of:

providing a linear track structure having one end positioned proximate the framing station and a free end;

providing a carousel positioned proximate the assembly line, defining a plurality of sides each adapted to receive a framing gate, and mounted for rotation about a central axis to bring successive sides of the carousel into a position proximate the free end of the track structure and in linear alignment with the track structure; and

moving a gate positioned on a side of the carousel in alignment with the track structure from the carousel side, onto the track structure, and along the track structure to the framing station with a transfer device.

20. The method of claim 19 further comprising the step of engaging a gate with a trolley operative to move the gate along the track structure to the framing station.

21. The method of claim 20 further comprising the step of supporting a framing gate positioned on the respective side of the carousel, wherein each side of the carousel includes a carousel track structure configured to be aligned with the free end of the linear track structure as the respective side of the carousel is moved into a position proximate the free end of the linear track structure.

22. The method of claim 21 further comprising the steps of:

latching a framing gate to a respective side of the carousel with a first latch device;

supporting the carousel with a base structure;

latching the carousel to the base structure with a second latch device; and

actuating the second latch device with a latch control device operative in response to arrival of a carousel side at a position proximate the free end of the linear track structure to latch the carousel to the base structure and releasing the first latch device to release the framing gate from the carousel and allow the trolley to move the released framing gate along the linear track structure to the framing station.

23. The method of claim 22 further comprising the step of:

operating a third latch device to latch the trolley to a framing gate, the third latch device actuated prior to release of the first latch device and following engagement of the second latch device, and wherein the first latch device is released following engagement of the third latch device to allow the trolley to move the released framing gate to the framing station.

24. The method of claim 23 further comprising the steps of:

defining a support surface with the base structure;

generating an air cushion between the support surface and an underface of the carousel to lift the carousel off of the support surface; and

applying a turning force to the lifted carousel to rotate the carousel about the central axis to bring successive sides of the carousel into position proximate the free end of the track structure and in linear alignment with the track structure.

25. The method of claim 24 further comprising the step of releasing the second latch, wherein the second latch device is released following the air cushion generating step, thereafter the applying turning force step is actuated to bring a respective side of the carousel carrying a respective framing gate into alignment with the linear track structure, thereafter the second linear latch device actuating step is actuated to latch the carousel to the base structure, thereafter the third latch device operating step is actuated to latch the trolley to the respective framing gate, thereafter the framing gate latching step is actuated so that the first latch device is released to release the respective framing gate from the carousel, and thereafter actuating the trolley to move the respective framing gate to the framing station.

26. The method of claim 25, further comprising the step of deactivating the air cushion generating step to lower the carousel back down to the support surface prior to actuation of the trolley to move the respective framing gate to the framing station.

27. A method for use in delivering framing gates to a framing station on a vehicle body assembly line, the transfer apparatus comprising the steps of:

positioning a linear track structure having one end proximate the framing station and a free end;

moving a carousel positioned proximate the assembly line, defining a plurality of sides each adapted to receive a framing gate, to bring the carousel into a position proximate the free end of the track structure and in linear alignment with the track structure; and

operating a transfer device operative to move a gate positioned on a side of the carousel in alignment with the track structure from the carousel side, onto the track structure, and along the track structure to the framing station.

28. The method of claim 27 further comprising the step of operating a trolley operative to engage a gate and move the gate along the track structure to the framing station.

29. The method of claim 28, further comprising the step of supporting a framing gate, wherein each side of the carousel includes a carousel track structure for supporting a framing gate positioned on the respective side of the carousel and configured to be aligned with the free end of the linear track structure as the respective side of the carousel is moved into a position proximate the free end of the linear track structure.

30. The method of claim 29 further comprising the step of:

latching a framing gate to a respective side of the carousel with a first latch device;

supporting the carousel with a base structure;

latching the carousel to the base structure with a second latch device; and

actuating the second latch device with a latch control device operative in response to arrival of a carousel side at a position proximate the free end of the linear track structure to latch the carousel to the base structure and release the first latch device to release the framing gate from the carousel and allow the trolley to move the released framing gate along the linear track structure to the framing station.

31. The method of claim 30 further comprising the step of:

actuating a third latch device to latch the trolley to a framing gate, the third latch device actuated prior to release of the first latch device and following engagement of the second latch device, and wherein the first latch device is released following engagement of the third latch device to allow the trolley to move the released framing gate to the framing station.