Abstract: A modular vehicle assembly system and methods for increased flexibility and adaptability of a high volume assembly facility which builds several vehicle models. In one example, the invention includes modular assembly equipment (AE) support pallets which are shipped to vendors for installation of selected AE equipment devices that are specific to a predetermined assembly operation and then validation tested prior to shipment. The modular AE pallets and AE devices are quickly installed and easily removable for maintenance or replacement. In other examples, modular AE support platforms and safety fencing are used to support ground level assembly operation and safer working environment.

Abstract: A modular reconfigurable vehicle assembly pallet system and method are disclosed. In one example, a plurality of modular assembly plates are assembled having vehicle locators positioned specifically for a particular model vehicle. The assembled vehicle-specific plates are easily installed on a universal pallet positioned along an assembly line in an assembly sequence. The vehicle-specific modular plates can be quickly interchanged on the assembly pallet to thereby reconfigure the assembly pallet to coordinate with changing vehicle build assembly sequences.

Abstract: Methods and apparatuses for continuous fastener feeding for sequentially delivering single fasteners to a fastener installation device are disclosed. In one embodiment the apparatus includes a first fastener reel for supporting a first fastener tape securing a plurality of fasteners and a second fastener reel for supporting a second fastener tape for securing a plurality of fasteners. A fastener tape joining device positioned downstream of the first and second fastener reels receives the respective first and the second fastener tapes and selectively engage the first and second fastener tapes when one of the fastener tapes becomes depleted of fasteners.

Abstract: A combination component handling and connecting device connectable to a multi-axis robot for use in moving and connecting components and subassemblies includes a housing and an actuator fixedly connected to the housing. The actuator includes an actuating link movable from a first position to a second position. Connected to the actuating link is an end effector for concurrent movement with the actuating link. The component handling and connecting device includes a clamp having a first jaw and a second jaw. The second jaw is connected to the actuating link for selectively moving the second jaw toward the first jaw operative to engage a component.

Abstract: Methods and apparatuses for continuous fastener feeding for sequentially delivering single fasteners to a fastener installation device are disclosed. In one embodiment the apparatus includes a first fastener reel for supporting a first fastener tape securing a plurality of fasteners and a second fastener reel for supporting a second fastener tape for securing a plurality of fasteners. A fastener tape joining device positioned downstream of the first and second fastener reels receives the respective first and the second fastener tapes and selectively engage the first and second fastener tapes when one of the fastener tapes becomes depleted of fasteners.

Abstract: A robotic end effector system and method having a plurality of end effectors which are selectively suitable for particular applications on a workpiece. The end effectors include a resident controller adapted to execute tasks specific to the end effector and are rapidly attachable and removable from the robot for easy change over to different workpieces.

Abstract: A method for positioning a vehicle assembly support device in a vehicle assembly station positioned along an assembly line. The method includes use of a plurality of locator pads selectively engaged with respective receiver sockets to position a vehicle support pallet in the X and Y coordinate directions. Vertical supports are used to position the vehicle support pallet in the Z coordinate direction. In one example, at least one receiver is a four-way positional receiver and at least one receiver is a two-way positional receiver. In another example, each receiver socket includes rollers which engage the respective locator pad to bias the vehicle support pallet towards the desired X and Y coordinate position.

Abstract: An inverted carrier lift and method is disclosed. The inverted carrier lift includes a trolley movable along an overhead conveyor and a carrier for supporting a workpiece to undergo an assembly or manufacturing process. The carrier is movable relative to the trolley from a raised position to a lowered position by a motor mounted engaged with a lifting mechanism onboard the trolley. On rotation of the motor, the carrier and supported workpiece is lowered or raised to position the workpiece in the workstation for processing. The workpiece may be disengaged by the carrier for support of the workpiece by one of many different fixtures depending on the processing. Following processing, the workpiece is re-engaged by the carrier, moved to a raised position and the trolley is transferred to a subsequent workstation.

Abstract: Methods and apparatuses for continuous fastener feeding for sequentially delivering single fasteners to a fastener installation device are disclosed. In one embodiment the apparatus includes a first fastener reel for supporting a first fastener tape securing a plurality of fasteners and a second fastener reel for supporting a second fastener tape for securing a plurality of fasteners. A fastener tape joining device positioned downstream of the first and second fastener reels receives the respective first and the second fastener tapes and selectively engage the first and second fastener tapes when one of the fastener tapes becomes depleted of fasteners.

Abstract: Methods for welding motor vehicle body component subassemblies at a weld stations are disclosed. First and second pallets may be arranged for reciprocal movement between a load/unload station and the weld station and the pallets are alternately moved from a load/unload station to the weld station while the other pallet is moved from the weld station to a load/unload station. Each pallet may have a plurality of substations for receipt of component subassemblies and, while each pallet is at the load/unload station, the component subassembly at each substation is moved to the next successive substation and a further component is added to the moved component.

Abstract: A combination component handling and connecting device connectable to a multi-axis robot for use in moving and connecting components and subassemblies includes a housing and an actuator fixedly connected to the housing. The actuator includes an actuating link movable from a first position to a second position. Connected to the actuating link is an end effector for concurrent movement with the actuating link. The component handling and connecting device includes a clamp having a first jaw and a second jaw. The second jaw is connected to the actuating link for selectively moving the second jaw toward the first jaw operative to engage a component.

Abstract: An adaptable end effector useful to accommodate a wide variety of components, component geometries and variations in component geometries. In one example, the end effector includes a movable arm and at least three fingers each having a gripping tool for engagement of the component with variable and/or programmable holding force preventing relative movement.

Abstract: An automated guided cart (AGC) that is configured to travel along a cart path according to generally non-precision movements is implemented to support a build process requiring precise positioning of vehicle build devices. In an example of a method of use, a vehicle build device for the build process is engaged with the AGC. When the AGC travels proximate a build operation area, the AGC can be secured in a dimensionally fixed position, with the result that both the AGC and a vehicle build device engaged with the AGC are located in precise positions. Based on the precise location of the vehicle build device, the vehicle build device can be interfaced with robots or other automated equipment according to preprogrammed and/or precise movements to carry out a build process.

Abstract: A vehicle body positioning and locking devices for use in assembling a vehicle body positioned on a movable vehicle support positioned at a vehicle build station. The locking device includes a remote vehicle locking device for selectively securing and locking a vehicle body to a support pallet. The support pallet is accurately and precisely positioned at a build station through alignment and inserting engagement of locating pads in at least one four-way and at least one two way receiver mounted to a build station foundation. A compliant body clamp design is included to provide a desired clamping force between the pallet and a vehicle body across a range of motion of the body clamp to accommodate vehicle build variances.

Abstract: A device and method for assembling parts, products or machines in a random build order that integrates or combines the delivery of loose components to be assembled on a carriage that itself supports the device being assembled along an assembly line path of travel. The loose parts onboard the carriage that also supports the device being progressively assembled substantially improves the logistics in an assembly plant and efficiency in building the part, product or device, for example a vehicle sheet metal body.

Abstract: A vehicle body positioning and locking devices for use in assembling a vehicle body positioned on a movable vehicle support positioned at a vehicle build station. The locking device includes a remote vehicle locking device for selectively securing and locking a vehicle body to a support pallet. The support pallet is accurately and precisely positioned at a build station through alignment and inserting engagement of locating pads in at least one four-way and at least one two way receiver mounted to a build station foundation. A compliant body clamp design is included to provide a desired clamping force between the pallet and a vehicle body across a range of motion of the body clamp to accommodate vehicle build variances.

Abstract: A method of sequentially performing a plurality of jointing operations includes positioning an automated device to form a mechanical joint into a workpiece and forming a mechanical joint into the workpiece. Once the mechanical joint is formed, the workpiece is scanned to generate data indicating the surface geometry of the workpiece at a location including the mechanical joint. One or more geometric features of the surface geometry are identified, and if the identified geometric features are within respective predetermined specification thresholds, the automated device is repositioned to form a subsequent mechanical joint into the workpiece.

Abstract: A modular vehicle assembly system and methods for increased flexibility and adaptability of a high volume assembly facility which builds several vehicle models. In one example, the invention includes modular assembly equipment (AE) support pallets which are shipped to vendors for installation of selected AE equipment devices that are specific to a predetermined assembly operation and then validation tested prior to shipment. The modular AE pallets and AE devices are quickly installed and easily removable for maintenance or replacement. In other examples, modular AE support platforms and safety fencing are used to support ground level assembly operation and safer working environment.

Abstract: A vehicle body positioning device for use in assembling a vehicle body positioned on a movable vehicle support positioned at a vehicle build station. The movable vehicle support includes a support pallet which is accurately and precisely positioned at a build station through alignment and inserting engagement of locating pads in at least one four-way and at least one two way receiver mounted to a build station foundation.

Abstract: A combination component handling and connecting device connectable to a multi-axis robot for use in moving and connecting components and subassemblies includes a housing and an actuator fixedly connected to the housing. The actuator includes an actuating link movable from a first position to a second position. Connected to the actuating link is an end effector for concurrent movement with the actuating link. The component handling and connecting device includes a clamp having a first jaw and a second jaw. The second jaw is connected to the actuating link for selectively moving the second jaw toward the first jaw operative to engage a component.