System and method for repairing and re-aligning damaged vehicle body and frame structures

• US 20090234480A1
• Filed: 03/11/2009
• Published: 09/17/2009
• Est. Priority Date: 03/12/2008
• Status: Active Grant

• Current Assignee: Gregory E. Marion
• Original Assignee: Gregory E. Marion
• Inventors: Marion, Gregory E.
• Granted Patent: US 8,170,697 B2
• Time in Patent Office: Days
• US Class Current: 700/98
• CPC Class Codes: G06F 16/00 Information retrieval; Database structures therefor; File system structures therefor

Abstract

Systems and methods for evaluating damage to a vehicle and controlling a vehicle repair process to bring all aspects of the damaged vehicle back within manufacturer'"'"'s specification during repair. Processes for evaluating, measuring and repairing specified reference points on a vehicle are described. The processes include an incremental examination and repair of affiliated reference points to bring them back into specified positions with respect to a datum, each other and the centerline of the vehicle. The processes also include the determinations of the three-dimensional dislocations of reference points from their specified positions and make a three-dimensional determination of a force vector to direct the application of force to return each reference point to its specified position. A computer system implementing the vehicle control processes provides automated or semi-automated systems of vehicle repair.

Claims

1. A method for repairing a damaged vehicle comprising:

a. selecting a specification database for the vehicle type to be repaired, wherein the database establishes positional measurements for a plurality of reference points for the selected vehicle;

b. establishing a datum;

c. selecting and holding an initial reference point with respect to the datum;

d. selecting a reference point to be repaired;

e. determining the deviation of the selected reference point from its specified position and establishing the deviation by three-dimensional measurements with respect to the datum;

f. calculating a force vector for defining the direction of force to be applied to the reference point to cause the reference point to be moved to its specified position;

g. applying force to the reference point in the direction of the force vector;

h. establishing when the reference point is returned to its specified position and discontinuing the application of force;

i. holding the reference point at that specified position; and

j. repeating steps d through i for each of the plurality of reference point on the damaged vehicle that require repair.

2. The method of claim 1 wherein the specified positional measurements for the plurality of reference points includes:

a. datum measurements for each of the reference points from a datum;

b. separation measurements of ones of the plurality of reference points with respect to associated related other ones of the plurality of reference points; and

c. centerline measurements of selected ones of the plurality of reference points from the centerline of the vehicle.

3. The method of claim 2 wherein the step of establishing includes the steps of:

a. measuring the datum height of the reference point and comparing it to the specified datum height and determining when the measured datum height and the specified datum height are substantially equal;

b. measuring the separation distance of the reference point from a related reference point and comparing it to the specified separation distance and determining when the measured separation distance and the specified separation distance are substantially equal; and

c. measuring the centerline distance of the reference point to the centerline, when applicable, and comparing it to the specified centerline distance and determining when the measured centerline distance and the specified centerline distance are substantially equal.

4. The method of claim 3, wherein the steps are computer implemented.

5. A computer implemented system for repairing a damaged vehicle comprising:

database-selecting means for selecting a specification database for the vehicle type to be repaired, wherein the database establishes positional measurements for a plurality of reference points for the selected vehicle;

datum-establishing means for establishing a datum;

first selecting means for selecting an initial reference point with respect to the datum;

second selecting means for selecting a reference point to be repaired;

deviation-determining means for determining the deviation of the selected reference point from its specified position and establishing the deviation by three-dimensional measurements with respect to the datum;

calculating means for calculating a force vector for defining the direction of force to be applied to the reference point to cause the reference point to be moved to its specified position;

controlling means for controlling the application of force to the reference point in the direction of the force vector;

positional-establishing means for establishing when the reference point is returned to its specified position and discontinuing the application of force;

holding means for holding the selected reference point at its specified position; and

repeating means for repeating the repair process for each of the plurality of reference point on the damaged vehicle that require repair.

6. The system of claim 5 wherein the specified positional measurements for the plurality of reference points each include:

datum measurements for each of the reference points from a datum;

relational measurements of ones of the plurality of reference points with respect to associated related other ones of the plurality of reference points; and

centerline measurements of selected ones of the plurality of reference points from the centerline of the vehicle.

7. The system of claim 6 wherein the deviation-determining means includes:

datum-height measuring means for measuring the datum height of the reference point;

comparing means for comparing the datum height to the specified datum height;

datum-height comparing means for determining when the measured datum height and the specified datum height are substantially equal;

relational-measuring means for measuring the separation distance of the reference point from a related reference point and including relational comparing means for comparing the measured relational distance to the specified separation distance and determining when the measured separation distance and the specified separation distance are substantially equal; and

centerline-measuring means for measuring the centerline distance of the reference point to the centerline, when applicable, and including centerline comparing means for comparing measured centerline distance to the specified centerline distance and determining when the measured centerline distance and the specified centerline distance are substantially equal.

8. For use in a vehicle repair system, a method comprising:

a. identifying a reference point on a vehicle requiring repair;

b. determining the three-dimensional damaged position of the selected reference point position relative to its specified positional measurements with respect to a datum; and

c. calculating a force vector for establishing the optimum direction of application of force to move the reference point to its specified positional measurements,

whereby the minimal amount of force will be required to return the reference point to its specified positional measurements while causing minimal collateral damage to the vehicle during the repair of the reference point.

9. The method of claim 8, wherein

a. the step of determining includes measuring the deviations in the x-axis, y-axis and z-axis of the damaged position of the reference point with respect its positional specification with respect to the datum;

and

b. the step of calculating included calculating the slope of a vector originating at the damaged position and passing through the specified position of the reference point.

10. For use in a vehicle repair system, a computer implemented process comprising:

a. identifying a reference point on a vehicle requiring repair;

b. determining the three-dimensional damaged position of the selected reference point position relative to its specified positional measurements with respect to a datum; and

c. calculating a force vector for establishing the optimum direction of application of force to move the reference point to its specified positional measurements,

whereby the minimal amount of force will be required to return the reference point to its specified positional measurements while causing minimal collateral damage to the vehicle during the repair of the reference point.

11. The computer implemented process of claim 10, wherein

a. the step of determining includes measuring the deviations in the x-axis, y-axis and z-axis of the damaged position of the reference point with respect its positional specification with respect to the datum;

and

b. the step of calculating includes calculating the slope of a vector originating at the damaged position and passing through the specified position of the reference point.

12. For use in a vehicle repair system, the method comprising:

a. selecting the sector of a vehicle needing repair of the structure;

b. repairing the structure of the selected sector by bringing the body reference points into specification and validating alignment of the structure in the repaired sector;

c. repeating steps ‘

a’ and

‘

b’

for all damaged sectors of the vehicle;

d. determining whether there is any undamaged sector, including determining whether it is necessary to check alignment of any undamaged sector;

e. checking alignment of the sector by determining whether any reference point is out of tolerance with respect to alignment;

f. determining whether further alignment repair is required and when necessary making alignment repair; and

g. continuing steps ‘

e’ and

‘

f’

until all undamaged sectors are determined to be within tolerance with respect to alignment.

13. The method of claim 12, wherein the step of repairing for each dislocated reference point within the sector, includes the steps of

a. measuring the three-dimensional deviation of the reference point from its positional specification requirements;

b. calculating a force vector to direct direction of force application at the reference point;

c. applying force in the direction of the force vector until the reference point is returned to its positional specification requirements;

d. validating whether or not all specified positional requirements have been met within prescribed tolerances to assure repair to specification and alignment of the structure, and, if not met, making further repair until satisfied; and

e. holding the reference point pending further repair activity.

14. The method of claim 13, wherein the specified positional measurements for the plurality of reference points includes:

a. datum measurements for each of the reference points from a datum;

b. separation measurements of ones of the plurality of reference points with respect to associated related other ones of the plurality of reference points; and

c. centerline measurements of selected ones of the plurality of reference points from the centerline of the vehicle.

15. The method of claim 14, wherein validating includes the steps of:

a. measuring the datum height of the reference point after repair and comparing it to the specified datum height and determining when the measured datum height and the specified datum height are substantially equal;

b. measuring the separation distance of the reference point after repair from a related reference point and comparing it to the specified separation distance and determining when the measured separation distance and the specified separation distance are substantially equal; and

c. measuring the centerline distance of the reference point after repair to the centerline, when applicable, and comparing it to the specified centerline distance and determining when the measured centerline distance and the specified centerline distance are substantially equal.

16. The method of claim 14, wherein validating alignment includes the steps of

a. determining whether or not positional specification measurements are satisfied within a prescribed tolerance, and, if not making further repair until satisfied;

b. determining whether or not relational specification measurements between related reference points are within prescribed tolerance, and, if not, making further repair until satisfied; and

c. determining for each reference point, whether or not diagonal measurements between the reference point being validated and a related reference point are required, and when required, comparing the diagonal measurement to a diagonal measurement between two related reference points to determine whether or not the two diagonal measurements are substantially equal, and adjusting the structure until the diagonal measurements are substantially equal; and

d. determining whether or not centerline specification measurements are satisfied within the prescribed tolerance, and, if not, adjusting the structure until satisfied,

whereby positional and alignment requirements will be satisfied.

17. The method of claim 16, wherein the steps are computer implemented.

18. For use in a vehicle repair system, the method comprising:

a. selecting a repair section initially including four related reference points symmetrically arranged in pairs,

b. selecting and holding a first reference point of a first pair;

c. selecting a diagonal reference point in a second pair;

d. repairing the diagonal reference point of the second pair to its specified positional measurements and holding it;

e. repairing the second reference point of the first pair to its specified positional measurements and holding it;

f. repairing the second reference point of the second pair to its specified positional measurements and holding it;

h. establishing another repair section by selecting a further pair of reference points related to one or the other of the pairs of reference points that have been repaired;

i. associating one of the further pair with the diagonal one of the selected related pair and associating the other diagonal one of the further pair to the other one of the selected pair;

j. separately repairing each one of the further pair of reference points to its specified positional measurements and holding; and

k. repeating steps ‘

f’

through ‘

j’

until all of the reference points that have been damaged have been repaired,

whereby the repair is advanced in incremental steps in both directions from the first pair and minimizes the force required to achieve repair of each of the selected reference points.

19. The method of claim 18, wherein each of the repairing steps utilizes the specified measurements for each of the reference points wherein the measurements include:

a. datum measurements for each of the reference points from a datum;

b. separation measurements of related ones of the reference points with respect to associated related other ones of the reference points;

c. centerline measurements of selected ones of the reference points from the centerline of the vehicle; and

d. diagonal measurements of selected pairs of reference points arranged in a repair section.

20. The method of claim 19, wherein repairing includes the steps of:

a. measuring the datum height of the reference point after repair and comparing it to the specified datum height and determining when the measured datum height and the specified datum height are substantially equal;

b. measuring the separation distance of the reference point after repair from a related reference point and comparing it to the specified separation distance and determining when the measured separation distance and the specified separation distance are substantially equal;

c. measuring the centerline distance of the reference point after repair to the centerline, when applicable, and comparing it to the specified centerline distance and determining when the measured centerline distance and the specified centerline distance are substantially equal; and

d. measuring the diagonal distances after repair for pairs of reference points that are affiliated in the repairing process, when applicable, and comparing the sets of diagonal measurements to determine whether or not the compared diagonal measurements are substantially equal,

whereby when the criteria of the specified measurements are satisfied, the reference points will be within specification and the vehicle will be aligned.

21. For use in a vehicle repair system, a computer system comprising:

a computer capable of executing programs and having an input and output system capable of receiving input signals and transmitting output signals;

a display for providing visual display of data and commands;

a printer for providing printed output of data and commands;

a database source for providing specifications for selected vehicle types;

a measurement system for receiving measurement signals from a plurality of sources and providing signals indicative of received measurement data to the computer in selected formats;

programs operable on the computer capable of processing input data for—

a. treating each reference point to be repaired by processing three-dimensional measurements indicative of the dislocation of the reference point from its specified position and determining a force vector to define the direction of application of force on the reference point to return it to its specified position as determined by the database;

b. incrementally processing successive repair sections comprised of selected reference points by causing each reference point in the repair section to be brought into its specified position as determined by the database; and

c. verifying that repaired reference points within a repair section have been repaired to positions that assure alignment of the vehicle being repaired as determined by the database;

whereby upon completion of repair of all of the selected reference points, the vehicle body has been repaired and is in alignment.

22. The system of claim 21 wherein the specified positional measurements for the plurality of reference points includes:

a. datum measurements for each of the reference points from a datum;

b. separation measurements of ones of the plurality of reference points with respect to associated related other ones of the plurality of reference points; and

c. centerline measurements of selected ones of the plurality of reference points from the centerline of the vehicle.

23. The method of claim 21, wherein the specified positional measurements for each of reference points includes:

a. datum measurements for each of the reference points from a datum;

b. separation measurements of ones of the reference points with respect to associated related other ones of the reference points; and

c. centerline measurements of selected ones of the reference points from the centerline of the vehicle.

24. The method of claim 23 wherein the repair of each of the reference points includes the steps of:

a. measuring the datum height of the reference point and comparing it to the specified datum height and determining when the measured datum height and the specified datum height are substantially equal;

b. measuring the separation distance of the reference point from a related reference point and comparing it to the specified separation distance and determining when the measured separation distance and the specified separation distance are substantially equal; and

c. measuring the centerline distance of the reference point to the centerline, when applicable, and comparing it to the specified centerline distance and determining when the measured centerline distance and the specified centerline distance are substantially equal.