Abstract: A vehicle body clinch nut feeder (22) includes a dispensing head (54) having an inlet passage (60) through which oriented clinch nuts (26) are fed single file. The leading clinch nut is moved laterally to between a pair of clamp members (64, 66) of a clamp (62) where a second feed actuator (80) subsequently moves the clamped clinch nut downwardly to an opening (78) in a delivery member (76) where a robot end effector (32) receives the clinch nut in preparation for a clinching operation. An alignment mount (58) supports the dispensing head (54) on a support (56) for a horizontal movement in perpendicular horizontal directions to insure alignment of the robot end effector (32) with the clinch nut (26) to be received.

Abstract: The present invention generally relates to a method and programmable apparatus for the assembly of body components to an automotive body that has undergone a progressive series of framing and welding steps so as to produce a structurally rigid body frame, termed a body-in-white. More specifically, this invention relates to creating a new net locating scheme (X-Y and Z Cartesian coordinate system) for a body-in-white to direct associated tooling to create net attachment features on a rigid body frame with respect to a new net locating scheme so that components may be attached to an automotive body at a net location eliminating the need for any slip plane attachment techniques.

Abstract: A method and apparatus for forming attachment pads in an inner body panel for the precise attachment of an outer body panel thereto. The apparatus positions a fixed anvil at a predefined net reference position while a face plate simultaneously “finds” the panel and is mechanically locked into position. Thereafter, the apparatus forms the inner body panel between a forming die and the fixed anvil. The face plate maintains the location of the surface metal around the die, resulting in the formation of a raised pad the outermost surface of which is at the predefined net reference position. A single such apparatus can form raised pads having different predefined net reference positions for different attachment locations. A reciprocating punch having a variable stroke length selectively provides either a hole or a slot in the raised pad.

Abstract: A method and apparatus for forming attachment pads on a panel for attachment of a clinch nut thereto. The panel is formed between a forming die and a fixed anvil, which occupies a predefined net reference position. A face plate simultaneously “finds” the panel and is mechanically locked into position using a novel force applying device. The face plate maintains the location of the surface metal around the forming die, thereby forming a raised pad at the predefined net reference position. The novel force applying device includes self-contained piston modules positioned in tandem. Each module includes a housing having a void and a piston mounted within the void. The piston includes a driven and drive surfaces, wherein fluid pressure acts against the driven surface to drive the piston in an advanced direction such that the drive surface of the piston abuts another piston for cumulative effect.

Abstract: A broach tool holding system (20) includes a pair of locator pins (46) rotatably mounted on a tool holder plate (36) to facilitate mounting and detachment of an associated broach tool (34). The broach tool (34) has a pair of locating openings (62) each of which has a locating hole (64) including round clearance surfaces (70) and round locating surfaces (72) that cooperate with the locator pins to provide the mounting in an accurately positioned location. The method of mounting the broach tool utilizing the rotatable locator pins (46) facilitates the mounting of the broach tool (34) with the locating holes that also facilitate the mounting and with securement being provided by clamps (74) for the broaching operation.

Abstract: A vehicle sheet metal hemming system (20) and method for hemming vehicle sheet metal outer and inner members (24 and 26) to each other is performed by prehemming and final hemming operations at a single station in cooperation with robot apparatus (42). A drive mechanism (98) has a rotary actuator (100) that moves a tool table (78) vertically to move tool heads (80) between outer idle positions and inner use positions as well as moving prehem tools (82) and final hem tools (84) of the tool heads so as to perform both the prehemming and the final hemming operations.

Abstract: A vehicle body assembly line (10) and method for assembling vehicle bodies utilizes electromagnetic gauging apparatus (44) to generate production gauge data of an assembly of formed sheet metal components, and an electrical controller (38) compares the production gauge data to design gauge data to detect any production deviation and is electrically connected to the assembly line to adjust the assembly of the formed sheet metal body components to correct any production deviation detected.

Abstract: A sheet metal washer system for cleaning metal blanks includes a washer cassette with an open bottom that is selectively mounted on a tank assembly, a drive motor assembly and a filter assembly. The washer cassette includes an inlet opening and an exit opening with upper and lower entry rollers having a first predetermined durometer positioned adjacent to the inlet opening and upper and lower exit rollers having a second predetermined durometer positioned adjacent the exit opening. Upper and lower manifolds for delivering cleaning fluid from the filter assembly to the interior of the washer cassette are positioned between the entry and exit rollers. The sheet metal blank is cleaned by the entry rollers and dried by the exit rollers, as it passes through the sheet metal washer. The washer cassette preferably includes a safety mechanism for locking the upper entry and exit rollers into a storage position when the washer system is not in use.

Abstract: A sheet metal washer system for cleaning metal blanks includes a washer cassette with an open bottom that is selectively mounted on a tank assembly, a drive motor assembly and a filter assembly. The washer cassette includes an inlet opening and an exit opening with upper and lower entry rollers having a first predetermined durometer positioned adjacent to the inlet opening and upper and lower exit rollers having a second predetermined durometer positioned adjacent the exit opening. Upper and lower manifolds for delivering cleaning fluid from the filter assembly to the interior of the washer cassette are positioned between the entry and exit rollers. The sheet metal blank is cleaned by the entry rollers and dried by the exit rollers, as it passes through the sheet metal washer. The washer cassette preferably includes a safety mechanism for locking the upper entry and exit rollers into a storage position when the washer system is not in use.

Abstract: A sheet metal washer system for cleaning metal blanks includes a washer cassette with an open bottom that is selectively mounted on a tank assembly, a drive motor assembly and a filter assembly. The washer cassette includes an inlet opening and an exit opening with upper and lower entry rollers having a first predetermined durometer positioned adjacent to the inlet opening and upper and lower exit rollers having a second predetermined durometer positioned adjacent the exit opening. Upper and lower manifolds for delivering cleaning fluid from the filter assembly to the interior of the washer cassette are positioned between the entry and exit rollers. The sheet metal blank is cleaned by the entry rollers and dried by the exit rollers, as it passes through the sheet metal washer. The washer cassette preferably includes a safety mechanism for locking the upper entry and exit rollers into a storage position when the washer system is not in use.

Abstract: A sheet metal washer system for cleaning metal blanks includes a washer cassette with an open bottom that is selectively mounted on a tank assembly, a drive motor assembly and a filter assembly. The washer cassette includes an inlet opening and an exit opening with upper and lower entry rollers having a first predetermined durometer positioned adjacent to the inlet opening and upper and lower exit rollers having a second predetermined durometer positioned adjacent the exit opening. Upper and lower manifolds for delivering cleaning fluid from the filter assembly to the interior of the washer cassette are positioned between the entry and exit rollers. The sheet metal blank is cleaned by the entry rollers and dried by the exit rollers, as it passes through the sheet metal washer. The washer cassette preferably includes a safety mechanism for locking the upper entry and exit rollers into a storage position when the washer system is not in use.

Abstract: An improved method and apparatus for attaching vehicle doors to a body such that the doors are attachable without further adjustment. A net body coordinate system is established for a welded vehicle frame, and upper and lower locating slots are pierced in hinge pillars of the vehicle frame relative to the net body coordinate system. An offline fixture is provided for setting upper and lower door hinges cross-car and forming a locating nubbin in the hinges relative to a door. The door is attached to the vehicle frame by engaging the locating nubbins in the door hinges with the locating slots in the vehicle hinge pillar.

Abstract: A sheet metal washer system for cleaning metal blanks includes a washer cassette with an open bottom that is selectively mounted on a tank assembly, a drive motor assembly and a filter assembly. The washer cassette includes an inlet opening and an exit opening with upper and lower entry rollers having a first predetermined durometer positioned adjacent to the inlet opening and upper and lower exit rollers having a second predetermined durometer positioned adjacent the exit opening. Upper and lower manifolds for delivering cleaning fluid from the filter assembly to the interior of the washer cassette are positioned between the entry and exit rollers. The sheet metal blank is cleaned by the entry rollers and dried by the exit rollers, as it passes through the sheet metal washer. The washer cassette preferably includes a safety mechanism for locking the upper entry and exit rollers into a storage position when the washer system is not in use.

Abstract: The present invention generally relates to a method and apparatus for the assembly of body components to an automotive body that has undergone a progressive series of framing and welding steps so as to produce a structurally rigid body frame, termed a body-in-white. More specifically, this invention relates to creating a new net locating scheme (X-Y-Z coordinate system) for a body-in-white to direct associated tooling to create net attachment features on said rigid body frame so that components may be attached to said automotive body at a net location eliminating the need for any slip plane attachment techniques.

Abstract: A linear blind broaching machine (10) includes a base (22), a broaching ram assembly (24), a linear tool slide (26) supported on the base by linear antifriction bearings (90) and a support block (92) mounted between the base and the linear tool slide below a broaching ram of the broaching ram assembly to provide support to the linear tool slide during blind broaching. The linear tool slide has an elongated construction including an elongated positioning block (114) against which blind broaches are laterally positioned, and an electric servomotor (108) drives the linear tool slide (26) to provide indexing thereof between broaching movements of the broaching ram. A roller screw drive (54) driven by an electric servomotor (56) drives a broaching ram (44) supported by linear antifriction bearings 46.

Abstract: An apparatus for finding and immobilizing a vehicle chassis frame in its free state to form a net datum position in the design-intent position. The chassis frame is positioned between a plurality of opposed pads. The opposed pads are advanced from a retracted position to an advanced position to find the chassis frame. The opposed pads engage the chassis frame such that there is minimal displacement or deformation thereof. Once the opposed pads find their respective reference contact surfaces on the chassis frame, a locking mechanism is provided for locking the pair of opposed pads in place in the advanced position so as to immobilize the chassis frame therebetween. Subsequently, a forming and piercing mechanism may be used to fabricate locating features net to the frame fixture and in design-intent position on the chassis frame.

Abstract: A support grid (20) and method for making the support grid to support a vehicle seat bottom foam bun (24) utilizes a peripheral metallic wire (28) and sets of longitudinally and laterally extending metallic straps (38, 48) that are secured by end welds (58) to the peripheral wire and by autogenous intermediate welds (60) to each other. The end welds (58) can also be autogenous welds and as with the autogenous intermediate welds (60) can be made by laser welding or electric resistance welding.

Abstract: An assembly line (14) having particular utility for use in assembling sheet metal parts includes a work station (18) having one or more production part trays (32, 34), a pilot part tray (36) and an indexer (38) that indexes these part trays in a transverse direction to a direction of conveyance (C) of the assembly line to permit one of the two production part trays (32, 34) to be used for production or the pilot part tray (36) to be used for a future pilot test. Detachable couplings (56) allow the production and pilot part trays to be moved to a maintenance station (42, 44) that is outside of the assembly line work area (25).

Abstract: A linear blind broaching machine (10) includes a base (22), a broaching ram assembly (24), a linear tool slide (26) supported on the base by linear antifriction bearings (90) and a support block (92) mounted between the base and the linear tool slide below a broaching ram of the broaching ram assembly to provide support to the linear tool slide during blind broaching. The linear tool slide has an elongated construction including an elongated positioning block (114) against which blind broaches are laterally positioned, and an electric servomotor (108) drives the linear tool slide (26) to provide indexing thereof between broaching movements of the broaching ram. A roller screw drive (54) driven by an electric servomotor (56) drives a broaching ram (44) supported by linear antifriction bearings 46.

Abstract: A power transmission member (20) is provided by a spline rolling method and apparatus (36) that includes a pair of racks (38) for providing splines (24) with ends (34) opposing each other in a precisely spaced relationship at an annular groove (30) that is utilized to provide snap ring or other fastener positioning for axially locating the member during use.