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: 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 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: 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 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: 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 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.

Abstract: An overhead conveyor or transport system is disclosed where at least one carriage is supported on a plurality of rollers rotatably mounted in fixed overhead locations spaced along a path of travel. At least one motor is provided for driving a portion of the plurality of rollers in rotation along at least one segment of the path of travel. Each carriage has at least one elongate support member operably engagable with the rollers for movement along the path of travel in response to rotation of the rollers. The elongate support member is continuously engagable with at least two rollers simultaneously while the corresponding carriage is moved along the path of travel. Each carriage or carrier hangs downwardly below the rotational axis of the overhead rollers.

Abstract: A multi-axis articulatable robot with a weld gun having a pair of opposing arms, where at least one arm is movable relative to the other arm to apply pressure to a workpiece during a welding operation. At least one of the opposing arms of the weld gun can be rotatable or translatable relative to the other arm. At least one arm is moved relative to the other arm by an inverted roller screw linear actuator. The robot can include an electric controller for controlling the operation of the actuator of the weld gun as an additional axis of the robot movement. The actuator can be mounted on either of the opposing arms.

Abstract: A rotatable frame mounted on a base with trunnions. The frame can support a workpiece on more than one surface and can have workpiece engaging devices such as clamps, locating pins or nesting fixtures on both sides. The engaging devices can be different on different sides of the frame. The frame can be rotated by an electric motor, a pneumatic motor or a hydraulic motor. The frame can be expandable to accommodate frames of different sizes. The workstation can have a plurality of trunnion mounted fixtures positioned next to each other and a robot moveable between the fixtures. The frames can be replaced with a lifting device moving along an overhead rail. The frame includes an aperture positioned along the rotational axis of the frame for communicating power from an external power source to workpiece engaging devices.

Abstract: A pinch type weld gun wherein the weld arms are pivotally mounted on the frame structure via a ball bearing structure including annular members of insulative material positioned in apertures in the weld arms, inner races fixedly mounted on a common pivot pin, outer races positioned within the respective insulative annular members, and ball races positioned between the respective inner races and respective outer races. A shunt is fixedly secured at one end thereof to a gun electrode and fixedly secured at another end thereof to the gun transformer, and the other end of the shunt defines a coolant passage communicating with the transformer coolant passage system whereby coolant may be delivered to the transformer coolant passage system through the coolant passage in the other end of the shunt.

Abstract: A lowerator for an assembly system of the type including at least one rail defining a path of travel with respect to at least one workstation, and a conveyor for transporting a workpiece along the rail. The conveyor includes a trolley moveable along the rail and a carrier moveable with respect to the trolley. The carrier supports a workpiece during movement with respect to the workstation. The carrier is vertically positionable between a raised position and lowered position with respect to the trolley. The lowerator moves the carrier between the raised and lowered positions and cycles a latch for securing the carrier to the trolley when in the raised position. The lowerator includes at least one lifter or actuator defining a path of travel in at least a first direction, where the lifter actuates the latch to uncouple the trolley and carrier before moving the carrier into the lowered position at the workstation so that one or more processing operations can be performed on the workpiece.

Abstract: A clamping and locating fixture includes a hollow body, a pin mountable to the body, a locking arm positionable within the body locatable between two positions and a drive pin moveable within the body to engage the locking arm. A workpiece can be directed to a clamping position by the guide pin. The pin includes an aperture allowing a locking projection of the locking arm to extend therethrough and over a workpiece to clamp the workpiece for a processing operation. The locking projection can be retracted through the aperture while the workpiece is being located or is being removed. The drive pin can be moved within the body to engage a cam follower of the locking arm. The drive pin can be supported during movement by one or more rollers mounted in the body. The drive pin can include a pin body and a pin member moveably associated with one another to selectively define the position of a cam surface.

Abstract: A clamping and locating fixture includes a hollow body, a pin or angled plate mountable to the body, a locking arm positionable within the body locatable between two positions and a drive pin moveable within the body to engage the locking arm. A workpiece can be directed to a clamping position by the guide pin or angled plate. The pin or plate includes an aperture allowing a locking projection of the locking arm to extend therethrough and over a workpiece to clamp the workpiece for a processing operation. The locking projection can be retracted through the aperture while the workpiece is being located or is being removed. The drive pin can be moved within the body to engage a cam follower of the locking arm.

Abstract: A workstation having multiple robots and multiple fixtures for processing multiple workpieces along two processing paths. A first fixture can be positioned on the first processing path and a second fixture can be positioned on the second processing path. The multiple robots are positioned between the two paths and are moveable to process workpieces moving along both the first and second paths. The robots can be welding robots. The robots can be independently moveable with respect to each other to enhance the efficiency of the workstation. The robots can have overlapping ranges of movement so that every portion of the workpiece can be processed by at least two of the robots.

Abstract: A plurality of robots are positioned on a rotatable table for transporting parts to be processed through a plurality of work stations positioned around the periphery of the table. Each robot can carry a workpiece from one work station to the next. The rotation of the table moves the robot from one workstation to the next while carrying a part to be processed. Each robot can be independently movable relative to the other robots and each robot can be independently movable relative to the table. Each robot can include a welder for processing the workpiece independent of the workstation or during movement between work stations. Each robot can carry a plurality of differently configured workpieces between the work stations.