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 motor vehicle car body framing apparatus for use at a welding station, the apparatus including a gate having a frame structure and a plurality of tooling members carried by the frame structure for use in positioning components of the vehicle body at the welding station for welding. The tooling members are mounted on the frame structure by a plurality of mounting brackets. Each mounting bracket includes a base member mounted on the frame structure and a riser mounted on the base and mounting a respective tooling member. The riser is fixedly mounted on the base by a single central fastener bolt which may include a reduced diameter portion sized to breakaway in response to predetermined impact against the riser. The interface between the riser and the base comprises a plurality of contact points arranged in concentric relation with respect to the fastener bolt.

Abstract: A method and apparatus for assembling motorcycle frames includes a conveyor defining a path of travel and a pallet movable along the conveyor through a workstation. The pallet supports a rotatable frame for receiving individual components and/or sub-assemblies in fixed relationship with respect to one another in a geometry fixture. The angular position of the rotatable frame and supported geometry fixture can be reoriented about an axis of rotation by engagement with a drive motor. The rotatable frame is normally locked in an angular orientation with respect to the pallet until released by engagement with a lock release actuator or key. The pallet is supported on a movable section of the conveyor, which can be guided between raised and lowered positions with respect to the workstation to accurately and repeatably position the support pallet with respect to the workstation for automated processing operations at the workstation.

Abstract: A motor vehicle car body framing apparatus for use at a welding station, the apparatus including a gate having a frame structure and a plurality of tooling members carried by the frame structure for use in positioning components of the vehicle body at the welding station for welding. The tooling members are mounted on the frame structure by a plurality of mounting brackets. Each mounting bracket includes a base member mounted on the frame structure and a riser mounted on the base and mounting a respective tooling member. The riser is fixedly mounted on the base by a single central fastener bolt which may include a reduced diameter portion sized to breakaway in response to predetermined impact against the riser. The interface between the riser and the base comprises a plurality of contact points arranged in concentric relation with respect to the fastener bolt.

Abstract: An apparatus for positioning a workpiece carrier with respect to a workstation can include an encoder reader located in a fixed position at a workstation for generating a signal in response to interaction with at least one encoder strip, a workpiece carrier movable along a path of travel through the workstation, and having an encoder strip connected thereto, the encoder strip operably interacting with the encoder reader located at the workstation, and a non-direct drive or friction drive engaging the workpiece carrier for moving the carrier along the path of travel through the workstation, the non-direct drive or friction drive responsive to the signal from the encoder reader in a closed loop feedback control system. The encoder reader can be selected from a group consisting of an optical encoder reader, a magnetic encoder reader, and any other absolute positioning encoder reader.

Abstract: A motor vehicle car body framing apparatus for use at a welding station, the apparatus including a gate having a frame structure and a plurality of tooling members carried by the frame structure for use in positioning components of the vehicle body at the welding station for welding. The tooling members are mounted on the frame structure by a plurality of mounting brackets. Each mounting bracket includes a base member mounted on the frame structure and a riser mounted on the base and mounting a respective tooling member. The riser is fixedly mounted on the base by a single central fastener bolt which may include a reduced diameter portion sized to break away in response to predetermined impact against the riser. Each mounting bracket further includes means defining a triangulated mounting interface between the base and the riser arranged in concentric relation to the fastener bolt.

Abstract: An apparatus for assembling an automotive body on an assembly line having a right-hand body subassembly line, a left-hand body subassembly line and an underbody subassembly line, for delivery to a pallet transport system for movement through a body framing subassembly line. The apparatus includes an overhead transport system for transporting automotive components along at least one of the subassembly lines and for conveying the automotive components along a pallet transport system on the body framing subassembly line. The overhead transport system includes a trolley movable along a single overhead rail, a carriage slidably movable relative to the trolley, and a plurality of antler nests. Each antler nest is individually engageable with the carriage. The apparatus also includes a lowerator for transferring components from the overhead transport system to a geometry fixture at a workstation along the subassembly line.

Abstract: A car body framing apparatus for use at a welding station for welding a plurality of loosely assembled vehicle body components. The apparatus includes a gate having an open frame structure including skeletal members and tooling members mounted on the frame structure by a plurality of mounting brackets. Each mounting bracket includes a planar platform structure mounting a respective tooling member and a U-shaped mounting structure sized to be fitted over a respective skeletal member, having a cross-sectional configuration complimentary to the cross-sectional configuration of the skeletal member, and welded to the skeletal member over substantially the entire U-shaped extent of the mounting structure whereby to provide a strong welded attachment of the bracket to the skeletal member and provide stiffening reinforcement for the skeletal member.

Abstract: An apparatus for positioning a workpiece carrier with respect to a workstation can include an encoder reader located in a fixed position at a workstation for generating a signal in response to interaction with at least one encoder strip, a workpiece carrier movable along a path of travel through the workstation, and having an encoder strip connected thereto, the encoder strip operably interacting with the encoder reader located at the workstation, and a non-direct drive or friction drive engaging the workpiece carrier for moving the carrier along the path of travel through the workstation, the non-direct drive or friction drive responsive to the signal from the encoder reader in a closed loop feedback control system. The encoder reader can be selected from a group consisting of an optical encoder reader, a magnetic encoder reader, and any other absolute positioning encoder reader.

Abstract: An apparatus moves a plurality of transport media along a path of travel. The plurality of transport media define at least two groups of transport media, where each group of transport media has substantially identical transverse dimensions with respect to one another within one group of transport media, while having substantially different transverse dimensions with respect to another group of transport media. The apparatus includes a plurality of rollers rotatably mounted in fixed locations spaced along a path of travel. At least one motor is provided for driving at least one of the rollers in rotation. At least one transport media is supported on the rollers for movement along the path of travel in response to rotation of the roller by the motor. Each transport media has at least one elongate support member continuously engageable with at least two rollers simultaneously while the transport media moves along the path of travel.

Abstract: An apparatus moves a plurality of transport media along a path of travel. The plurality of transport media define at least two groups of transport media, where each group of transport media has substantially identical transverse dimensions with respect to one another within one group of transport media, while having substantially different transverse dimensions with respect to another group of transport media. The apparatus includes a plurality of rollers rotatably mounted in fixed locations spaced along a path of travel. At least one motor is provided for driving at least one of the rollers in rotation. At least one transport media is supported on the rollers for movement along the path of travel in response to rotation of the roller by the motor. Each transport media has at least one elongate support member continuously engageable with at least two rollers simultaneously while the transport media moves along the path of travel.

Abstract: An apparatus and method for randomly interchanging up to four pairs of side framing gates at a framing station of a vehicle assembly line while maintaining a predetermined build cycle time interval of the assembly line. The system employs first and second carousels positioned on opposite sides of the assembly line upstream of the framing station and third and fourth carousels positioned on opposite sides of the production line downstream of the framing station.

Abstract: An apparatus and process for assembling individual body components of a body-in-white vehicle with respect to one another to form a unitary vehicle body including a framing workstation for receiving and positionally locating an underbody member of the vehicle, and for receiving and positionally locating at least one upper body member of the vehicle with respect to the underbody member. The framing workstation establishing a predetermined geometry of the individual body components, while forming the unitary vehicle body. At least one self-piercing rivet tool for securing the at least one upper body member of the vehicle to the underbody member of the vehicle to form and maintain the predetermined geometry of the unitary vehicle body with self-piercing rivets.

Abstract: A workstation and method for processing a plurality of workpieces includes at least one material handling robot movable along a processing path for supporting a workpiece to be moved along the processing path. At least one station can be defined by at least one processing position adjacent the processing path for receiving workpieces to be processed when delivered and positioned by the at least one material handling robot. Interchangeable end effecters can be connected to the material handling robot for holding and supporting different configurations of workpieces. The material handling robot can disengage from the end effecter at the processing position, to allow engagement with a processing tool for performing additional processing operations on the workpiece. A flexible body workstation for assembling workpieces can use multiple robots and/or multiple fixtures for processing different workpiece configurations in any sequential order along two processing paths.

Abstract: An apparatus and method for randomly interchanging up to four pairs of side framing gates at a framing station of a vehicle assembly line while maintaining a predetermined build cycle time interval of the assembly line. The system employs first and second carousels positioned on opposite sides of the assembly line upstream of the framing station and third and fourth carousels positioned on opposite sides of the production line downstream of the framing station.

Abstract: A method and apparatus for assembling motorcycle frames includes a conveyor defining a path of travel and at least one pallet movable along the conveyor through at least one workstation. The pallet supports at least one rotatable frame for receiving individual components and/or sub-assemblies in fixed relationship with respect to one another in a geometry fixture. The angular position of the rotatable frame and supported geometry fixture can be reoriented about an axis of rotation by engagement with a drive motor. The rotatable frame is normally locked in an angular orientation with respect to the pallet. When the movable section of the conveyor and supported pallet are moved, the movable section of the conveyor is guided between raised and lowered positions with respect to the workstation, and the support pallet is accurately and repeatably positioned with respect to the workstation for automated processing operations at the workstation.

Abstract: A weld gun for performing a welding operation on a workpiece includes a pair of opposing arms, at least one arm movable relative to the opposing arm to apply pressure to the workpiece during a welding operation. A pair of identical or mirror image side plates support components of the weld gun to establish critical dimensions of the components relative to one another, while preventing tolerance buildup of critical dimensions at critical points. A guide block is connected to one of the opposing arms. The guide block has a non-circular aperture formed therein. An electrode adapter has a non-cylindrical rod portion slidably received in the non-circular aperture formed in the guide block for preventing rotation of the electrode adapter. A hose fitting is attachable directly to a rear end of the electrode adapter for communicating with an inlet water port and an outlet water port formed in the electrode adapter for providing a routing of coolant directly through the electrode adapter only.

Abstract: A weld gun including a frame structure, a weld arm mounted on the frame structure, an electrode mounted on the weld arm and including an electrode cap at one end of the electrode, a transformer, and a shunt fixedly secured at one end thereof to another end of the electrode and fixedly secured at another end thereof to the transformer.

Abstract: An anchoring system for a support structure with respect to a floor of a manufacturing facility can include at least one floor anchor plate roughly positioned along a path of travel. A template can be engaged with the floor anchor plate for accurately locating the position of studs to be attached to the floor anchor plate. In the case of two floor anchor plates, the plates are preferably positioned equidistantly along a transversely extending line on opposite sides of the path of travel. The template can define one or more apertures adjacent each of the floor anchor plates for receiving a stud to be attached thereto. A stud can be inserted and guided into position within each aperture to attached to the adjacent floor anchor plate. The elevation of the support structure can be adjusted by turning lower nuts threadingly engaged with the studs.

Abstract: An apparatus for assembling an automotive body on an assembly line having a right-hand body subassembly line, a left-hand body subassembly line and an underbody subassembly line, for delivery to a pallet transport system for movementthrough a body framing subassembly line. The apparatus includes an overhead transport system for transporting automotive components along at least one of the subassembly lines and for conveying the automotive components along a pallet transport system on the body framing subassembly line. The overhead transport system includes a trolley movable along a single overhead rail, a carriage slidably movable relative to the trolley, and a plurality of antler nests. Each antler nest is individually engageable with the carriage. The apparatus also includes a lowerator for transferring components from the overhead transport system to a geometry fixture at a workstation along the subassembly line.