Ergonomic work operation method and apparatus

• US 9,033,088 B2
• Filed: 02/14/2013
• Issued: 05/19/2015
• Est. Priority Date: 02/14/2013
• Status: Active Grant

• Current Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Salek, Richard Joseph, Ignat, Cristian, Cheeseman, William Brad, Sharp, Kevin W., Linka, Brian, Albon, Rod James, Szentimrey, John Andrew, Eng, Jonathan Philip Kenneth
• Primary Examiner(s): Shriver, II, J. Allen
• Assistant Examiner(s): CLEMMONS, STEVE M
• Application Number:
  US13/767,308
• Publication Number:
  US 20140224559A1
• Time in Patent Office: 824 Days
• Field of Search: 180167-169, 180/907, 280/32.5, 280/32.6, 318/587, 318/591, 701/23, 297/217.7, 297/344.12, 297/326.11, 297/423.1
• US Class Current: 180/168
• CPC Class Codes: A47C 9/022 movably mounted on a working-table or the like for hairdressers A47C1/08
• CPC Class Codes: B60L 2200/24 Personal mobility vehicles
• CPC Class Codes: B60N 2/00 Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles railway seats B61D33/00; cycle seats B62J1/00; aircraft seats B64D11/06, B64D25/04, B64D25/10
• CPC Class Codes: B66F 11/04 for movable platforms or cabins, e.g. on vehicles, permitting workmen to place themselves in any desired position for carrying out required operations Working platforms on fork-lift trucks B66F9/127; vehicle aspects of service vehicles B60P3/14; platforms for cleaning windows A47L3/02; devices for rescuing persons from buildings A62B1/02; liftable or lowerable platforms for use on ladders E06C7/16; maintenance travellers for bridges E01D19/10; scaffolds on an extensible sub-structure E04G1/22
• CPC Class Codes: B66F 9/063 Automatically guided
• CPC Class Codes: G05D 1/0263 using magnetic strips

Abstract

A method and apparatus for ergonomically supporting a worker while performing a work operation includes an automatic guided vehicle capable of moving a seat carrying the worker between a first non-work position relative to a work piece and a second work position at which the worker performs the work operation. The automatic guided vehicle includes controls to enable the worker to ergonomically position the angle of a seatback relative to a seat bottom and the height of the seat relative to the automatic guided vehicle for ergonomic support of the worker while performing the work operation. Under program control, the automatic guided vehicle is movable from one work position to another work position and/or back to the non-work position.

Claims

1. An apparatus for supporting a worker in an ergonomic working position with respect to a workpiece during a work operation comprising:

an automatic guided vehicle having a powered drive wheel and a base supported by the powered drive wheel, the powered drive wheel movable in a programmed path of movement along a guidepath;

a seat mounted on the base of the automatic guided vehicle for supporting a worker in an ergonomic work position when the automatic guided vehicle is in a work position; and

a controller configured to integrate the automatic guided vehicle for operation within an assembly line.

2. The apparatus of claim 1, wherein the powered drive wheel is moveable in the programmed path of movement along the guidepath between a first position adjacent the assembly line and a second position within the assembly line, the controller configured to direct movement of the powered drive wheel along the guidepath between the first and second positions.

3. The apparatus of claim 2 further comprising a memory including a control program executable by the controller, the control program defining a sequence of movement of the powered drive wheel between the first and second positions.

4. The apparatus of claim 1, wherein the seat is mounted on a platform carried on the base of the automatic guided vehicle, the apparatus further comprising:

a footrest attached to the platform for supporting a foot of the worker; and

a height adjustment mechanism coupled between the base of the automatic guided vehicle and the platform for simultaneously adjusting a height of the platform and the footrest relative to the base.

5. The apparatus of claim 4 further comprising:

manually operated actuators carried on at least one of the seat and the footrest to enable the worker to adjust a position of the seat and to control movement of the automatic guided vehicle.

6. The apparatus of claim 4 further comprising:

at least one foot operated pedal carried on the platform to control a direction of movement of the automatic guided vehicle by the activation of the at least one foot pedal.

7. The apparatus of claim 6 further comprising a sensor operably connected to the at least one foot pedal, the sensor configured to send an angular position signal to the controller indicative of a position of the at least one foot pedal, the controller configured to direct movement of the powered drive wheel between the first and second positions in response to the angular position signal.

8. The apparatus of claim 2 wherein:

the second position is a work position and the first position is a non-work position.

9. The apparatus of claim 8 wherein:

the work position includes a plurality of distinct work positions.

10. The apparatus of claim 9 wherein the controller is configured to direct movement of the powered drive wheel from one of the plurality of work positions to another one of the plurality of work positions.

11. The apparatus of claim 4, wherein the footrest is positioned in a fixed vertical relation to the seat.

12. A method for performing a manufacturing operation while ergonomically supporting a worker, comprising:

providing an assembly line having a longitudinal axis defining a path of travel of a workpiece;

providing an automatic guided vehicle having a seat for ergonomically supporting a worker when seated in the seat, the automatic guided vehicle following a fixed guidepath under program control, the guidepath traversing the longitudinal axis of the assembly line; and

advancing the automatic guided vehicle along the fixed guidepath from a non-work position adjacent the assembly line to a work position located within the assembly line to enable the worker to perform a work operation on the workpiece while ergonomically supported by the seat.

13. The method of claim 12 comprising:

moving the automatic guided vehicle from the work position to the non-work position.

14. The method of claim 12 comprising:

providing the work position as a plurality of distinct work positions arranged in a grid pattern.

15. The method of claim 14 wherein:

moving the automatic guided vehicle under program control from one of the plurality of distinct work positions to another one of the plurality of distinct work positions.

16. The method of claim 14, wherein at least a portion of the distinct work positions are arranged on opposite sides of the fixed guidepath.

17. The method of claim 12 further comprising:

maintaining the workpiece in a stationary position during the work operation.

18. The method of claim 12 further comprising:

providing the workpiece as an automotive vehicle sheet metal body with a plurality of welds; and

performing the work operation as a weld chisel check on at least one of the welds on the automotive vehicle body.

19. The method of claim 12, where the seat includes a seat bottom and a seat back, the method further comprising:

mounting the seat to a platform supported on a base of the automatic guided vehicle by a height adjustment mechanism coupled between the platform and the base, the platform including a foot rest for supporting a foot of the worker; and

concurrently adjusting a height of the platform and the footrest relative to the base of the automatic guided vehicle in response to operating the height adjustment mechanism.

20. A manufacturing system for supporting a worker in an ergonomic working position with respect to a workpiece during a work operation, the manufacturing system comprising:

an assembly line including a workstation, a longitudinal axis of the assembly line defining a path of travel of the workpiece;

an automatic guided vehicle having a powered drive wheel and a base supported by the powered drive wheel, the powered drive wheel movable in a programmed path of movement along a guidepath traversing the longitudinal axis of the assembly line; and

a seat mounted on the base of the automatic guided vehicle for supporting a worker in an ergonomic work position when the automatic guided vehicle is in a work position.

21. The manufacturing system of claim 20, wherein the seat is mounted on a platform carried on the base of the automatic guided vehicle, the manufacturing system further comprising:

a footrest attached to the platform for supporting a foot of the worker; and

a height adjustment mechanism coupled between the base of the automatic guided vehicle and the platform for simultaneously adjusting a height of the platform and the footrest relative to the base.

22. The manufacturing system of claim 21, further comprising at least one foot operated pedal carried on the platform to control a direction of movement of the automatic guided vehicle by activating the at least one foot pedal.

23. The manufacturing system of claim 20 further comprising manually operated actuators carried on one of the seat and the automatic guided vehicle to enable the worker to adjust a position of the seat and control movement of the automatic guided vehicle.

24. The manufacturing system of claim 20, wherein the work position is located within the work station and the automatic guided vehicle is movable from the work position to a non-work position adjacent the work station.

25. The manufacturing system of claim 20, wherein the work position includes a plurality of distinct work positions, the automatic guided vehicle, under program control, is movable from one of the plurality of work positions to another one of the plurality of work positions.

26. The manufacturing system of claim 25, wherein at least a portion of the distinct work positions are located within the work station.

27. The manufacturing system of claim 25, wherein the plurality of distinct work positions are arranged in a grid pattern.