Abstract: A modular production system and method includes an endless transport path defining a loop. A plurality of work cells in which processes are performed on a workplace are disposed in a sequence along the transport path. The work cells include an inner spot welding cell, an inner remote laser welding cell, and an outer roller flanging and laser welding cell. A transporter follows the transport path and selectively transfers the workplace between the work cells along the transport path. The transporter selects at least some of the work cells and makes a stop at the selected work cells, and the transporter bypasses any unselected work cells.

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 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 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 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 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 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 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 robotic roller hemming apparatus includes a mounting member having a face for operative connection of the mounting member to a multi-axis controllable robotic arm, and a bracket extending from the face. A tracking roller is mounted on the bracket. A slide plate is operatively connected to the bracket and slidable relative to the bracket. A hemming roller is operatively connected to the slide plate proximate the tracking roller for roller hemming nested metal panels therebetween the hemming and tracking rollers. A slide actuator connects the bracket and the slide plate for moving the hemming roller toward and away from the tracking roller.

Abstract: A sheet metal trimming, flanging and forming apparatus using EMP includes a panel support having a support surface that generally conforms to a geometry of at least a portion of a metal panel. A securement device is disposed in proximity to the support surface and is moveable between a resting position and a working position relative to the support surface. An EMP coil is mounted around the securement device. The securement device secures the metal panel on the support surface, and in the working position the EMP coil is disposed in close proximity to the metal panel at a distance that promotes bending of the metal panel when an electromagnetic pulse is generated by the EMP coil.

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 robotic turntable drive arrangement in a robotic roller hemming system includes a turntable having a top plate and a lower frame. The top plate is rotatable about the lower frame. The turntable further includes a plurality of lock positions. The arrangement also includes a robot having an arm adapted for engagement with the turntable top plate. Movement of the robot arm while the robot arm is engaged with the turntable top plate rotates the turntable top plate.

Abstract: A roller type hemming apparatus includes a support member having a slide bore. A ball screw extends through the support member into the slide bore. A bearing is engaged with the ball screw inside the slide bore. The apparatus further includes a guided slide member having a first portion received in the slide bore and a second portion extending outside of the slide bore. The slide member first portion has a receiver. A resilient member is set in the receiver. The resilient member operably engages the bearing, the bearing being disposed outside of the receiver. The apparatus also includes a retaining plate having an opening therein. The retaining plate is mounted to the support member adjacent the slide bore for retaining the slide member first portion in the slide bore. A hem roller is rotatably mounted to the slide member second portion.

Abstract: A pre-hemming apparatus for use with a hemming die includes a driving member adapted to be centrally disposed below the hemming die. A plurality of link arms are operatively, pivotally connected to the driving member. A lever arm is operatively connected to each link arm. A flanging member is operatively connected to each lever arm at an end thereof. A plurality of mounts for supporting the lever arms are adapted to be mounted to a side of the hemming die. Each lever arm is pivotally connected to one of the mounts intermediate ends of the lever arm. An actuator is operatively engagable with the driving member. Actuation of the driving member moves the flanging members towards the hemming die through the lever arms and the link arms for pre-hemming, and away from the hemming die cycling the apparatus.

Abstract: An apparatus for horizontally actuating hemming and stamping die sets includes a horizontal base support and a roller device horizontally mounted thereon. A linear guidance system is set in and a drive support is vertically attached to the base support. A drive mechanism is supported and an anvil die set is held by the drive support. A vertical platen rests on top of the base support and is loosely guided by the linear guidance system. A punch die set is held by the vertical platen and a plurality of bushings are set therein. At least three guide shafts are secured to the anvil die set and each is engaged to one of the bushings of the punch die set. A plurality of link bars are attached to the vertical platen via link bar attachments and coupled to the drive mechanism. Actuation of the drive mechanism horizontally moves the vertical platen.

Abstract: An apparatus for horizontally actuating hemming and stamping die sets includes a horizontal base support and a roller device horizontally mounted thereon. A linear guidance system is set in and a drive support is vertically attached to the base support. A drive mechanism is supported and an anvil die set is held by the drive support. A vertical platen rests on top of the base support and is loosely guided by the linear guidance system. A punch die set is held by the vertical platen and a plurality of bushings are set therein. At least three guide shafts are secured to the anvil die set and each is engaged to one of the bushings of the punch die set. A plurality of link bars are attached to the vertical platen via link bar attachments and coupled to the drive mechanism. Actuation of the drive mechanism horizontally moves the vertical platen.

Abstract: A closure panel hemming apparatus includes a lower support supporting a lower hemming die and an upper support spaced from and mounted above the lower support supporting an upper hemming die. The upper and lower supports are relatively vertically moveable for bringing the dies toward and away from one another. At least one guide post interconnects the upper and lower supports and maintains alignment of the upper and lower supports during movement thereof. A plurality of actuators of the ball screw or rack and pinion type is driveably connected to draw together the upper and lower supports bringing the dies together for edge hemming preformed metal panels nested between the dies.