Abstract: A palletized framing system for a motor vehicle body assembly system in which the pallet with a body structure positioned thereon is positioned at the framing station on balls to establish the vertical Z dimension with the pallet free to float on the balls in longitudinal X and lateral Y dimensions, whereafter positioners carried by one of the gates of the framing station engage and lock onto the pallet to precisely position the pallet and the body structure at the framing station at X and Y dimensions corresponding to the precisely attainable X and Y positioning of the gate.

Abstract: A method and apparatus for assembling a complex product in a parallel process system wherein a collection of components are provided for assembling the complex product. The present invention involves transferring the collection of components to one of a plurality of similar computerized assembly cells through the use of a transport system. The collection of components is automatically assembled into the complex product through the use of the computerized assembly cells. The complex product is then transferred from one of the assembly cells to a computerized test cell, where the complex product is tested to ensure for the proper dimensioning and functioning of the complex product. The complex product is then transferred from the test cell via the transport system to either a part reject area or conveyor, if the product is defective, or to an automatic dunnage load or part return system, if the product is not defective.

Abstract: Disclosed herein is a sensing device for use in providing positive feedback of the position of a vehicle body securing device used to selectively secure a vehicle body to a vehicle body support movable along a path of travel. A vehicle body securing device is selectively movable between a locked position and an unlocked position. An indicator is connected to the securing device and is reciprocally movable to and from a target area when the securing device is in one of the locked position and the unlocked position. A sensor has a field of view selectively alignable with the target area. The sensor is operable to detect when the indicator is positioned at the target area to provide a positive indication of the position of the securing device.

Abstract: A flexible leak test apparatus and method for leak testing a variety of workpieces having various multiple configurations with at least one internal cavity and at least one aperture leading therefrom. The flexible leak test apparatus and method provide a plurality of leak test fixtures adaptable to receive the workpieces. Each leak test fixture has a bottom portion and a top portion that engage one another when the workpieces are loaded in the bottom portion of the leak test fixture. The leak test fixtures are shuttled in and out of the workstation, and a manipulator loads and unloads the workpieces into and out of the bottom portion of the leak test fixtures. The leak test fixtures seal the apertures in the workpieces so that the workpieces can be leak tested by pressurizing the internal cavity of the workpiece.

Abstract: A combination component handling and connecting device connectable to a multi-axis robot for use in moving and connecting components and subassemblies includes a housing and an actuator fixedly connected to the housing. The actuator includes an actuating link movable from a first position to a second position. Connected to the actuating link is an end effector for concurrent movement with the actuating link. The component handling and connecting device includes a clamp having a first jaw and a second jaw. The second jaw is connected to the actuating link for selectively moving the second jaw toward the first jaw operative to engage a component.

Abstract: A thermal metal spraying apparatus for use with a thermal metal spraying torch for applying a metal coating to a workpiece through a torch spraying nozzle having a spraying orifice. The thermal metal spraying apparatus provides a substantially tubular shroud having a first end and a second end adaptable to concentrically receive the torch spraying nozzle. The shroud has an opening at the second end, wherein the opening is selectably alignable with the spraying orifice. A drive mechanism is connected to the shroud and is operable to translate the shroud between a first position, wherein the opening at the second end is not aligned with the spraying orifice, thereby preventing the spraying of the metal coating on the workpiece, and a second position, wherein the opening at the second end is aligned with the spraying orifice permitting the spraying of the metal coating toward the workpiece.

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.

Abstract: A hemming head device and method for hem forming one or more edges of deformable material. The hemming head device includes dual biasing spring members which provide a resistive force whether the hemming wheel is in a push hemming operation on an exterior joint edge or in a pull hemming operation on an interior joint edge. The device further includes a quick connect device for selectively connecting hemming wheels and other forming devices to the head and a gauge to measure the relative position or resistive force applied on the forming member by the biasing members. A method for hem forming a workpiece using dual biasing spring members is also disclosed.

Abstract: A method and apparatus for managing the delivery of component parts and tooling to a robotic welding assembly positioned on a motor vehicle body assembly line. Automatic guided vehicles deliver component parts from a source of parts to a parts staging area on the robotic welding assembly including a substage awaiting area, a substage in-use area and a substage empty area, and further automatic guided vehicles deliver tooling from a tooling management area to the robotic welding assembly whereafter the tooling, upon model changeover, is moved to a tooling use area proximate the assembly line whereafter, upon further model changeover, the tooling is removed from the tooling use area and loaded onto an automatic guided vehicle for return to the tooling management area.

Abstract: A method and apparatus for managing the delivery of component parts and tooling to a robotic welding assembly positioned on a motor vehicle body assembly line. Automatic guided vehicles deliver component parts from a source of parts to a parts staging area on the robotic welding assembly including a substage awaiting area, a substage in-use area and a substage empty area, and further automatic guided vehicles deliver tooling from a tooling management area to the robotic welding assembly whereafter the tooling, upon model changeover, is moved to a tooling use area proximate the assembly line whereafter, upon further model changeover, the tooling is removed from the tooling use area and loaded onto an automatic guided vehicle for return to the tooling management area.

Abstract: An elevator assembly includes a carrier, a first arm, and a second arm. Each arm has a primary portion pivotally connected to the carrier and a secondary portion pivotally connected to the primary portion. A first gear system interconnects the first arm and the second arm for synchronous rotation with respect to the carrier in opposite directions. A pair of second gear systems establish a geared relationship between the secondary portions of the arms and the carrier. A support member is connected to the secondary portions of the arms, wherein rotation of the primary portions of the arms with respect to the carrier drives the support member between a neutral position and at least a first extended position.

Abstract: A method and apparatus for providing motor vehicle sub-assemblies with unrestricted model mix and quick changeover between models. The apparatus includes a track; a carriage mounted for longitudinal movement along the track between first and second positions; and first and second turrets rotatably mounted on the carriage at longitudinally spaced locations and each including a plurality of circumferentially spaced individual faces and unique tooling fixtures on the respective faces for receiving unique work piece components corresponding to a plurality of motor vehicle body styles.

Abstract: A weld gun in which the first weld arm is fixedly but removably connected to the weld gun body and the second weld arm includes a first arm segment, pivotally mounted at one end thereof on the gun body and pivotally connected at another end thereof to the gun actuator, and a second arm segment fixedly but removably connected atone end thereof to an intermediate portion of the first arm segment. Conversion of the gun from an X axis configuration to a Y axis configuration is achieved by removing the second arm segment from the first arm segment, removing the first weld arm from the body, rotating the second arm segment and the first weld arm through 90°, attaching the first arm to the first arm segment, and connecting the second arm segment to the body.

Abstract: A method and apparatus for automatically assembling a clutch of an automatic transmission of a motor vehicle. The method and apparatus includes providing an assembly station having an assembly table with a clutch fixture connected to the assembly table and adaptable to receive a clutch housing. At least one tray is connected to the assembly table and is adaptable to receive clutch components of the clutch. At least one robotic arm is engageable with the clutch housing and the clutch components for loading and unloading the clutch housing onto and from the clutch fixture and the clutch components from at least one tray. A manipulator connected to and in communication with the at least one robotic arm automatically engages an appropriate tool for assembling the clutch components into the clutch housing. At least one assembly fixture is removably connected to the clutch fixture and connectable to the clutch housing for assisting in the assembly of the clutch components to the clutch housing.

Abstract: A fastening device and method for mounting equipment to a framing member. The invention includes a single breakaway fastener that is pretentioned using a biasing member to fracture on a predetermined force applied to the fastened joint to avoid damage to the secured equipment. In one example the device and method includes the fastener having a reduced diameter portion that is positioned between an annular plate and the framing member.

Abstract: A method and apparatus for assembling a complex product in a parallel process system wherein a collection of components are provided for assembling the complex product. The present invention involves transferring the collection of the components to one of a plurality of similar computerized assembly cells through the use of a transport system. The collection of components is automatically assembled into the complex product through the use of the computerized assembly cells. The complex product is then transferred from one of the assembly cells to a computerized test cell, where the complex product is tested to ensure for the proper dimensioning and functioning of the complex product. The complex product is then transferred from the test cell via the transport system to either a part reject area or conveyor, if the complex product is defective, or to an automatic dunnage load or part return system, if the complex product is not defective.

Abstract: A method and apparatus for managing the delivery of component parts and tooling to a robotic welding assembly positioned on a motor vehicle body assembly line. Automatic guided vehicles deliver component parts from a source of parts to a parts staging area on the robotic welding assembly including a substage awaiting area, a substage in-use area and a substage empty area, and further automatic guided vehicles deliver tooling from a tooling management area to the robotic welding assembly whereafter the tooling, upon model changeover, is moved to a tooling use area proximate the assembly line whereafter, upon further model changeover, the tooling is removed from the tooling use area and loaded onto an automatic guided vehicle for return to the tooling management area.

Abstract: An apparatus for positioning a workpiece carrier with respect to a workstation can include a workpiece carrier movable relative to the workstation and having an encoder strip, at least one encoder reader located at the workstation for generating a signal in response to interaction with at least one encoder strip, and a drive engaging the workpiece carrier for moving the carrier relative to the workstation, the drive responsive to the signal from the encoder reader. A closed loop feedback control system can be provided for receiving the signal from the encoder reader, and for generating an output signal in response to the signal from the encoder reader in accordance with a program stored in memory.

Abstract: A fastening device and method for mounting equipment to a framing member. The invention includes a single breakaway fastener that is pretentioned using a biasing member to fracture on a predetermined force applied to the fastened joint to avoid damage to the secured equipment. In one example the device and method includes the fastener having a reduced diameter portion that is positioned between an annular plate and the framing member.

Abstract: A method and apparatus for providing motor vehicle sub-assemblies with unrestricted model mix and quick changeover between models. The apparatus includes a track; a carriage mounted for longitudinal movement along the track between first and second positions; and first and second turrets rotatably mounted on the carriage at longitudinally spaced locations and each including a plurality of circumferentially spaced individual faces and unique tooling fixtures on the respective faces for receiving unique work piece components corresponding to a plurality of motor vehicle body styles.