INTEGRATED VEHICLE PART DELIVERY AND BUILD SYSTEM

• US 20120304446A1
• Filed: 05/30/2012
• Published: 12/06/2012
• Est. Priority Date: 06/03/2011
• Status: Active Grant

• Current Assignee: Comau LLC (Stellantis NV)
• Original Assignee: Comau Incorporated (Stellantis NV)
• Inventors: Kilibarda, Velibor
• Granted Patent: US 9,513,625 B2
• Time in Patent Office: Days
• US Class Current: 29/430
• CPC Class Codes: B23P 21/004 the units passing two or more work-stations whilst being composed
• CPC Class Codes: B23P 2700/50 Other automobile vehicle parts, i.e. manufactured in assembly lines
• CPC Class Codes: G05B 19/41805 characterised by assembly
• CPC Class Codes: G05B 2219/31036 Load component into corresponding compartment, bin, storage before assembly
• CPC Class Codes: G05B 2219/31044 Assembly of modular products, variant configurability
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10T 29/49829 Advancing work to successive stations [i.e., assembly line]
• CPC Class Codes: Y10T 29/534 Multiple station assembly or disassembly apparatus
• CPC Class Codes: Y10T 29/53417 Means to fasten work parts together

Abstract

A device and method for assembling parts, products or machines in a random build order that integrates or combines the delivery of loose components to be assembled on a carriage that itself supports the device being assembled along an assembly line path of travel. The loose parts onboard the carriage that also supports the device being progressively assembled substantially improves the logistics in an assembly plant and efficiency in building the part, product or device, for example a vehicle sheet metal body.

Claims

1. A method for providing coordinated part delivery for use in a predetermined random build sequence in vehicle manufacturing assembly lines, the method comprising the steps of:

gathering a plurality of individual vehicle build components for at least a first and a second vehicle type, the first vehicle type different than the second;

loading selected parts for one of the first vehicle type on one of a plurality of movable carriages;

loading selected parts for one of the second vehicle type on another of the one of the plurality of carriages;

sequencing each of the respective loaded plurality of carriages in sequential order such that the respective carriages loaded parts coordinate with a predetermined sequence of the at least first and second vehicle types to be assembled;

supporting the first or second vehicle type to be progressively assembled with the respective carriage supporting the loaded build components for the respective first or second vehicle type;

progressively moving each loaded carriage along a path of the vehicle build; and

progressively removing selected build components from the respective carriages at a plurality of build stations along the assembly line to progressively assemble at least a portion of the respective first and second vehicle types.

2. The method of claim 1 wherein the step of loading selected parts on one of the plurality of carriages further comprises the step of positioning the plurality of components on at least one rack hanger integrated with the carriage.

3. The method of claim 2 further comprising the step of loading a partially completed first or second vehicle type on a deck portion of the carriage, the deck portion positioned adjacent to the at least one rack hanger and moveable relative to the rack hanger.

4. The method of claim 3 further comprising the step of reciprocally moving the carriage deck portion relative to the rack hangers to position the respective partially completed first or second vehicle type in a build position in a respective build station.

5. The method of claim 4 wherein the step of moving the carriage deck portion further comprises the steps of:

operably disengaging the deck portion from the rack hangers;

lowering the deck portion the build position; and

raising the deck portion for re-engagement to the rack hangers following completion of the build station assembly operations.

6. The method of claim 5 wherein the deck portion remains connected to the rack hangers and is telescopically guided relative to the deck hangers to and from the build position.

7. The method of claim 4 further comprising the step of transferring a tooling pallet into the build station to precisely position the partially assembled first or second vehicle type in the build station for assembly.

8. The method of claim 1 wherein the step of progressively removing selected build components from the carriages further comprises the steps of:

selectively engaging the build components by inverted robots positioned in the build station;

removing the selected build components from the part hangers positioned in the build station along the build path; and

connecting the selected components to the partially assembled first or second vehicle type.

9. The method of claim 1 wherein the step of loading selected parts on one of the plurality of carriages further comprises the step of loading the parts in a material sequencing area positioned distant from, but in communication with the manufacturing assembly line including assembly cells.

10. The method of claim 1 further comprising the step of returning the carriage to an area to be reloaded with the plurality of vehicle build components.

11. The method of claim 1 further comprising the step of engaging the carriage with an overhead conveyor for moving the carriage, the loaded build parts and the loaded first or second vehicle type along the vehicle build path as a single carriage unit.

12. An integrated vehicle part delivery system for use in random vehicle build order manufacturing and assembly, the system comprising:

a plurality of carriages, each carriage adapted for loading receipt and support of;

(a) one of a first and a second vehicle type to be progressively assembled, and

(b) a plurality of vehicle build components suitable for connection to a respective one of the first or the second vehicle type supported on the respective carriage;

a conveyor engageable with the respective plurality of carriages for transporting the carriages along a build path of travel; and

a plurality of build stations positioned along a build path of travel wherein on positioning of the carriage in a build station, the vehicle build components onboard the carriage are selectively removed from the carriage and connected to the first or second vehicle type on board the same carriage to progressively assemble the onboard vehicle type.

13. The system of claim 12 wherein at least one of the plurality of carriages further comprises:

a deck for supporting the one of the first or the second vehicle type; and

at least one part rack for supporting the plurality of vehicle components to be connected to the first of the second vehicle type onboard the carriage.

14. The system of claim 13 wherein the part rack further comprises:

a base;

a first hanger panel connected to the base;

a second hanger panel connected to the base angularly oriented with respect to the first hanger panel, the first and second hanger panels operable to support at least one of the plurality of build components as the carriage moves along the build path.

15. The system of claim 13 wherein the part rack is connected to the conveyor and the deck is selectively movable relative to the part rack.

16. The system of claim 15 wherein the carriage further comprises at least one telescopic post connected to the deck and the part rack, the post allowing relative movement between the deck and the part rack without complete separation of the deck from part rack.

17. The system of claim 12 further comprising at least one lift device positioned on the build station, the lift device engagable with the deck and operative to selectively move the deck relative to the part rack.

18. The system of claim 17 wherein the lift device includes a reciprocal rotating arm engagable with a portion of the deck for reciprocal movement of the deck from a carriage build station load position to a build position below the load position in the build station.

19. The system of claim 12 further comprising:

a tooling conveyor positioned in the build station transverse to the build path of travel; and

a tooling pallet engagable with the tooling conveyor, the tooling pallet selectively movable into the build station to removably connect to and precisely position one of the first or the second vehicle type positioned in the build station.

20. An integrated vehicle part delivery system for use in random vehicle build order manufacturing and assembly, the system comprising:

gathering a plurality of individual vehicle build components for at least a first and a second vehicle type, the first vehicle type different than the second;

means for loading selected parts for one of the first vehicle type on one of a plurality of movable carriages;

means for loading selected parts for one of the second vehicle type on another of the one of the plurality of carriages;

means for sequencing each of the respective loaded plurality of carriages in sequential order such that the respective carriages loaded parts coordinate with a predetermined sequence of the at least first and second vehicle types to be assembled;

means for supporting the first or second vehicle type to be progressively assembled with the respective carriage supporting the loaded build components for the respective first or second vehicle type;

means for progressively moving each loaded carriage along a path of the vehicle build; and

means for progressively removing selected build components from the respective carriages at a plurality of build stations along the assembly line to progressively assemble at least a portion of the respective first and second vehicle types.