Abstract: A steering roller head for hemming or seaming metal sheets includes a mounting flange that couples to an arm of a robot. The mounting flange is offset from a longitudinal axis of the steering roller head to reduce an operating envelope of the robot arm during a roller hemming process. The mounting flange can also be offset by a mounting angle from the longitudinal axis which allows for a further reduction in an operating envelope of the robot arm during a roller hemming process. Reducing the operating envelope of the robot arm can allow for additional robots or automated tooling to access the work piece during a roller hemming process. In addition, reducing the operating envelope of the robot arm allows for improved access to the work piece during a roller hemming process.

Abstract: A triangular hemming and stamping apparatus includes a stationary base that mounts a lower die set. Three guide posts are triangularly positioned on the base and extend generally vertically from the base. An upper fixed superstructure is supported by the three guide posts and fixedly spaced from the base. An upper slidable structural member that mounts an upper die set is slidably mounted on the guide posts between the base and the superstructure. An actuator is mounted on the superstructure and connected to the upper slidable structural member within an area within the guide posts. The actuator is not connected to nor associated with the guide posts, and the actuator is operable to move the upper slidable structural member toward and away from the base to perform hemming and stamping on a workpiece.

Abstract: A triangular hemming and stamping apparatus includes a stationary base that mounts a lower die set. Three guide posts are triangularly positioned on the base and extend generally vertically from the base. An upper fixed superstructure is supported by the three guide posts and fixedly spaced from the base. An upper slidable structural member that mounts an upper die set is slidably mounted on the guide posts between the base and the superstructure. An actuator is mounted on the superstructure and connected to the upper slidable structural member within an area within the guide posts. The actuator is not connected to nor associated with the guide posts, and the actuator is operable to move the upper slidable structural member toward and away from the base to perform hemming and stamping on a workpiece.

Abstract: A horizontally stacked hemming press includes a horizontally disposed base. A first vertical support is mounted on the base and disposed generally perpendicular to the base. A linear track is mounted on the base. A horizontally disposed die stack including a plurality of cooperably operable die sets are horizontally arranged in series and moveable along the linear track. Each die set includes a pair of vertically disposed die shoes. A guided press platen is horizontally moveable along the linear track. A second vertical support is mounted on the base distal from the first vertical support and disposed generally perpendicular to the base. A drive mechanism is supported by one of the supports and connected to the press platen for opening and closing the die sets. Actuation of the drive mechanism horizontally moves the press platen and thereby horizontally opens one of the die sets.

Abstract: A rotary wheelhouse roller hemming apparatus in accordance with the present invention includes a support and a rotary mechanism including a plurality of connected anvils driveably rotatable about an axis. The rotary mechanism is mounted on the support. Rotation of the rotary mechanism about the axis moves the anvils between use and standby, non-use positions.

Abstract: A combined motion control and brake apparatus and method includes a linear longitudinal rail, a bearing block supported on the linear longitudinal rail, a linear rail brake fixed to the linear longitudinal rail, a carrier connected to the rail brake and supported by the bearing block, a pair of linear cross slide rails fixed on the carrier, the cross slide rails disposed generally at right angles to the longitudinal rail, a cross slide bearing block mounted on each cross slide rail, a cross slide supported on the cross slide bearing block moveable in both longitudinal and lateral directions, relative to the longitudinal rails, the cross slide including an engagement feature, and an engager operable to engage the engagement feature to release the rail brake and to move the cross slide rail.

Abstract: A roller hemming system for hemming nested panels includes a single hemming workstation providing for tooling exchange operations simultaneous with hemming operations. A plurality of robots that perform tooling exchange at the hemming workstation, movement of nested panels through the system, and hemming operations on nested panels at the hemming workstation. Nested panels are inputted into the system and hemmed nested panel assemblies are outputted from the system.

Abstract: A roller hemming system for edge hemming vehicle closures from nested metal panels includes an anvil robot moveably supporting a hemming anvil having a working surface, a clamping spider cooperable with the anvil robot for clamping the nested metal panels on the working surface, an anvil register including a base and a registration feature for matingly positioning the hemming anvil thereto, a hemming robot including a multi-axis controllable arm, a roller hemming apparatus mounted on a distal end of the multi-axis arm, the roller hemming apparatus being moveable along edges of the nested metal panels on the anvil to hem the panels together.

Abstract: A die change method includes providing a press apparatus having a base and a ram, and a first die set including an upper die member and a lower die member. The lower die member is supported on the base and the upper die member is mounted on the ram. The ram is lowered into a closed, home position to mate the upper and lower die members and to perform an operation on a workpiece disposed between the die members. The ram is released from the upper die member. The ram is raised a minimum distance to provide minimal clearance for removing the upper and lower die members from the press. The mated upper and lower die members are moved out of the press with the workpiece held between the upper and lower die members.

Abstract: A robotic wheelhouse hemming apparatus includes a base. A multi-axis robot is mounted on the base. The robot includes an arm. A roller hemming head is mounted on an end of the arm for roller hemming. A slide mechanism is mounted for multi-directional movement on the base. A support is mounted on the slide mechanism. An anvil is supported on the support. A registration member is integral with the support and is engagable by the roller hemming head. The robot arm is operable to manipulate the roller hemming head into engagement with the registration member, and subsequent movement of the robot arm moves the support on the slide mechanism, thereby adjusting the position of the anvil relative to a workpiece to be hemmed.

Abstract: A horizontally stacked hemming press includes a horizontally disposed base. A first vertical support is mounted on the base and disposed generally perpendicular to the base. A linear track is mounted on the base. A horizontally disposed die stack including a plurality of cooperably operable die sets are horizontally arranged in series and moveable along the linear track. Each die set includes a pair of vertically disposed die shoes. A guided press platen is horizontally moveable along the linear track. A second vertical support is mounted on the base distal from the first vertical support and disposed generally perpendicular to the base. A drive mechanism is supported by one of the supports and connected to the press platen for opening and closing the die sets. Actuation of the drive mechanism horizontally moves the press platen and thereby horizontally opens one of the die sets.

Abstract: A robotic pallet drive arrangement in a robotic roller hemming system including a track and a plurality of pallets movable on the track. The arrangement also includes a robot having an arm adapted for engagement with the pallets. Movement of the robot arm while the robot arm is engaged with one of the pallets moves the pallet along the track.

Abstract: An integrated forming, assembly and inspection system includes a plurality of robotic material conveyors. The integrated system also includes a forming subsystem including sheet metal drawing apparatus, a roller hemming subsystem, and an inspection subsystem. The plurality of robotic material conveyors are operable to convey assembly workpieces to and from the subsystems.

Abstract: A robot positioned welding tip dresser assembly includes a pivot arm pivotally mountable on a welding gun apparatus. The pivot arm is pivotal about a pivot point. A welding tip dresser is mounted on a distal end of the pivot arm. A first retaining tab extends from the pivot arm. The first retaining tab includes an opening extending therethrough. At least one positioning mechanism is disposed relative to the pivot point and is cooperable with the first retaining tab to retain the pivot arm in one of a home position and a working position. The first retaining tab is engagable by end-of-arm tooling of a robot. The end-of-arm tooling is operable to release the positioning mechanism, and movement of the robot moves the pivot arm between the home and working positions.

Abstract: A method of roller hemming an inner panel and an outer panel includes providing a hem roller having an angled roller hemming surface, and adjusting a hem flange line by moving the hem roller axially and generally parallel to an anvil support surface.

Abstract: A roller hemming apparatus includes a linear actuator mountable on an end of a multi-axis robotic arm. The linear actuator includes a connector. A roller hemming head is mounted on the linear actuator by the connector. The roller hemming head includes at least one hem roller. The roller hemming head performs both push force and pull force roller hemming operations.

Abstract: A magnetically actuated roller head includes a linear actuator mountable on an end of a multi-axis robotic arm. The linear actuator includes a slide, a magnet operably connected to the slide and operable to urge the slide in a linear direction, and a connector disposed on a distal end of the slide. A roller hemming head is mounted on the linear actuator by the connector. The roller hemming head includes at least one hem roller.

Abstract: A closure panel forming and assembly process includes inputting partially stamped inner and outer panels into the assembly system and finished assemblies out. The invention is a manufacturing process for closure panel assemblies, doors, deck lids, hoods, liftgates and other similar panels. The process has a reduced stamping operation of only two die stages, with the first operation being a draw operation followed by a second operation of trim and pierce. These operations may be done at a satellite location which may be within the same facility or at an outside location. All additional metal forming operations are done at an assembly system.

Abstract: A method of laser welding metal automotive panel assemblies includes loading a panel and parts to be welded thereto onto a support anvil; engaging a pressure pad/clamping anvil and clamping the anvils together with adequate force on the pressure pad to maintain alignment of the panel and parts, the anvil including access locations, such as holes, for admitting laser welding beams to the panel and parts locations to be welded; and actuating a laser welding gun to direct the welding laser beams through the access locations and weld the parts and panel together into an assembly. The method may further include applying welding flux to the panel locations to be welded, applying locating and clamping devices between the anvils and applying adequate holding force while maintaining alignment of the anvils, resulting in positive fit up for welding.

Abstract: A die change method includes providing a press apparatus having a base and a ram, and a first die set including an upper die member and a lower die member. The lower die member is supported on the base and the upper die member is mounted on the ram. The ram is lowered into a closed, home position to mate the upper and lower die members and to perform an operation on a workpiece disposed between the die members. The ram is released from the upper die member. The ram is raised a minimum distance to provide minimal clearance for removing the upper and lower die members from the press. The mated upper and lower die members are moved out of the press with the workpiece held between the upper and lower die members.