Abstract: A flexible assembly line includes a common welding station having a first set of tooling adapted to engage and support a first type of vehicle frame and a second set of tooling adapted to engage and support a second type of vehicle frame. The first set of tooling is provided on a first side of a rotatable unit and the second set of tooling is provided on a second side of the rotatable unit such that the rotatable unit is rotatable to present either the first set of tooling or the second set of tooling for a welding operation. The flexible assembly includes a first dedicated welding station having dedicated tooling particularly adapted to engage and support only the first type of vehicle frame. The flexible assembly includes a second dedicated welding station having dedicated tooling particularly adapted to engage and support only the second type of vehicle frame.

Abstract: A welding method and system (4) using a robotic arm (10), a welding robot (18) and a welding table (2) placed at an angle from horizontal to hold two C-channels (6 and 8) facing each other to maintain position and be welded together. C-channels (6 and 8) face each other to form a closed channel at increased welding speed with less materials having resulting benefits including constant welding, less distortion, and less welding material. Welding begins with restraining C-channels (6 and 8) in conjunction with the angled welding table (2). A robotic arm (10) handles C-channels (6 and 8) to move, place and restrain them relative to each other and the welding table (2). A pressing tool (12) may be a set of pressure-exerting tools (26). A welding robot (18) with a seam finding system (24) preferably welds the restrained C-channels (6 and 8) from top to bottom.

Abstract: A system for positioning and welding a bracket 30 to a mounting surface, such as a vehicle side rail 40, including using a pivoting tool 20 on a moveable arm 10 that allows the bracket 30 to pivot to minimize the gap between the bracket 30 and its intended mounting surface. The pivoting tool 20 secures, positions near the surface, and allows the bracket 30 to pivot for a precise surface match. A welder 50 welds the bracket 30 to the surface with the gap minimized while the bracket 30 is held in the desired position. The pivoting tool 20 is preferably on an adjustable appendage 12 or combination end 60 mounted on a distal end of the arm 10. The flexible tooling does not require the bracket 30 to be forced with substantial pressure against the mounting surface.

Abstract: A process and system for measuring, positioning and welding a bracket 30 to a mounting surface, such as a vehicle side rail 40, to accomplish smooth and continuous bracket assembly. A bracket positioning tool 20 on a robotic arm 10 allows brackets 30 to adjust to minimize the gap between the bracket 30 and its intended mounting surface. The bracket positioning tool 20 positions brackets 30 near the surface, and allows brackets 30 to adjust for a precise surface match. With input from a second measurement, a welding robot 50 welds the bracket 30 to the surface with the gap minimized while the bracket 30 is held in position. The measurement system and bracket positioning with flexible tooling do not require the bracket 30 to be forced with pressure against the mounting surface. With robots, brackets can be consistently placed and welded in precise locations on varying mounting surfaces.

Abstract: A system for positioning and welding a bracket 30 to a mounting surface, such as a vehicle side rail 40, including using a pivoting tool 20 on a moveable arm 10 that allows the bracket 30 to pivot to minimize the gap between the bracket 30 and its intended mounting surface. The pivoting tool 20 secures, positions near the surface, and allows the bracket 30 to pivot for a precise surface match. A welder 50 welds the bracket 30 to the surface with the gap minimized while the bracket 30 is held in the desired position. The pivoting tool 20 is preferably on an adjustable appendage 12 or combination end 60 mounted on a distal end of the arm 10. The flexible tooling does not require the bracket 30 to be forced with substantial pressure against the mounting surface.

Abstract: A welding method and system (4) using a robotic arm (10), a welding robot (18) and a welding table (2) placed at an angle from horizontal to hold two C-channels (6 and 8) facing each other to maintain position and be welded together. C-channels (6 and 8) face each other to form a closed channel at increased welding speed with less materials having resulting benefits including constant welding, less distortion, and less welding material. Welding begins with restraining C-channels (6 and 8) in conjunction with the angled welding table (2). A robotic arm (10) handles C-channels (6 and 8) to move, place and restrain them relative to each other and the welding table (2). A pressing tool (12) may be a set of pressure-exerting tools (26). A welding robot (18) with a seam finding system (24) preferably welds the restrained C-channels (6 and 8) from top to bottom.