CA2659143C - Robotic high density welding body shop - Google Patents
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- CA2659143C CA2659143C CA2659143A CA2659143A CA2659143C CA 2659143 C CA2659143 C CA 2659143C CA 2659143 A CA2659143 A CA 2659143A CA 2659143 A CA2659143 A CA 2659143A CA 2659143 C CA2659143 C CA 2659143C
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- 238000003466 welding Methods 0.000 title claims abstract description 49
- 238000004891 communication Methods 0.000 claims description 13
- 239000000969 carrier Substances 0.000 claims 1
- 238000007726 management method Methods 0.000 abstract description 43
- 238000000034 method Methods 0.000 abstract description 26
- 239000000463 material Substances 0.000 description 26
- 230000000712 assembly Effects 0.000 description 19
- 238000000429 assembly Methods 0.000 description 19
- 238000004519 manufacturing process Methods 0.000 description 7
- 230000007246 mechanism Effects 0.000 description 6
- 239000011800 void material Substances 0.000 description 4
- 238000012423 maintenance Methods 0.000 description 3
- 239000012636 effector Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
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Abstract
A method and apparatus for managing the delivery of component parts and tooling to a robotic welding assembly positioned on a motor vehicle body assembly line. Automatic guided vehicles deliver component parts from a source of parts to a parts staging area on the robotic welding assembly including a substage awaiting area, a substage in-use area and a substage empty area, and further automatic guided vehicles deliver tooling from a tooling management area to the robotic welding assembly whereafter the tooling, upon model changeover, is moved to a tooling use area proximate the assembly line whereafter, upon further model changeover, the tooling is removed from the tooling use area and loaded onto an automatic guided vehicle for return to the tooling management area.
Description
ROBOTIC HIGH DENSITY WELDING BODY SHOP
BACKGROUND OF THE INVENTION
[0001] This invention relates to motor vehicle manufacturing and more particularly to a high density welding body shop to facilitate manufacture of motor vehicle bodies.
BACKGROUND OF THE INVENTION
[0001] This invention relates to motor vehicle manufacturing and more particularly to a high density welding body shop to facilitate manufacture of motor vehicle bodies.
[0002] Whereas a myriad of vehicle body shop configurations have been proposed or implemented, the typical motor body shop continues to require large amounts of manpower, continues to consume a large factory footprint, continues to require complex equipment and procedures to supply component parts to the assembly line, and continues to require complex equipment and procedures to exchange tooling to facilitate model changeover.
SUMMARY OF THE INVENTION
SUMMARY OF THE INVENTION
[0003] The invention provides a body shop configuration that provides unlimited flexibility with respect to manufacture of differing body styles; facilitates batch build with limited random potential; provides unmatched modularity with respect to tooling layout material aisles etc; provides optimum material management with respect to flexible delivery and staging and sequencing; optimizes material delivery; optimizes material loading;
optimizes fixture exchange, fixture maintenance and fixture staging; maximizes robot density; facilitates an optimum maintenance strategy; facilitates production scheduling and floor space utilization; desensitizes product architecture; desensitizes build sequence;
optimizes manpower utilization, traffic engineering, and equipment utilization; and facilitates engineering build, installation, maintenance, and material management.
optimizes fixture exchange, fixture maintenance and fixture staging; maximizes robot density; facilitates an optimum maintenance strategy; facilitates production scheduling and floor space utilization; desensitizes product architecture; desensitizes build sequence;
optimizes manpower utilization, traffic engineering, and equipment utilization; and facilitates engineering build, installation, maintenance, and material management.
[0004] The invention is specifically directed to a method and apparatus for managing a motor vehicle body shop assembly of the type including a body assembly line and a robotic welding assembly device (RAD) positioned on the assembly line. The invention methodology comprises providing at least one automotive guide vehicle (AGV), a source of parts located on parts racks, a tooling management area including first model tooling for use by the RAD to assemble a first motor vehicle model and second model tooling for use by the RAD to assemble a second motor vehicle model, means defining a movement path for the AGV extending from the source of parts and the tooling management area to the RAD and returning to the source of parts and the tooling management area, and means for guiding the at least one AGV for selective movement along the movement path between the source of parts, the tooling management area, and the RAD; and utilizing the at least one AGV to selectively deliver first model tooling and second model tooling to the RAD
for use in respectively assembling the first motor vehicle model and the second motor vehicle model, return the first model tooling or second model tooling not in use to the tooling management area, and to deliver full parts racks from the source of parts to the RAD and return empty parts racks to the source of parts.
for use in respectively assembling the first motor vehicle model and the second motor vehicle model, return the first model tooling or second model tooling not in use to the tooling management area, and to deliver full parts racks from the source of parts to the RAD and return empty parts racks to the source of parts.
[0005] According to a further feature of the invention methodology, the RAD defines a staging area including a substage awaiting area, a substage in-use area, and a substage empty area arranged sequentially along and proximate the movement path and, with a full first parts racks in the substage in-use area for use by the RAD, an empty second parts rack in the substage empty area, and a void in the substage awaiting area, an AGV
carrying a full third parts rack is moved from the source of parts to the staging area, the full third parts rack is loaded onto the substage awaiting area, the empty second parts rack is loaded onto the AGV, and the AGV is returned to the source of parts.
carrying a full third parts rack is moved from the source of parts to the staging area, the full third parts rack is loaded onto the substage awaiting area, the empty second parts rack is loaded onto the AGV, and the AGV is returned to the source of parts.
[0006] According to a further feature of the invention, following depletion of the parts from the full first parts rack at the substage in-use area, the now empty first parts rack is moved from the substage in-use area to the now empty substage empty area and the full third parts rack at the substage awaiting area is moved to the now empty substage in-use area for use by the RAD.
[0007] According to a further feature of the invention method, an AGV
carrying a full fourth parts rack is thereafter moved from the source of parts to the staging area, the full fourth parts rack is unloaded onto the substage awaiting area, the empty first parts rack is unloaded onto the AGV, and the AGV is returned to the source of parts.
carrying a full fourth parts rack is thereafter moved from the source of parts to the staging area, the full fourth parts rack is unloaded onto the substage awaiting area, the empty first parts rack is unloaded onto the AGV, and the AGV is returned to the source of parts.
[0008] According to a further feature of the invention methodology, the movement of an AGV carrying a full parts rack from the source of parts to the staging area initially comprises movement of the AGV to the substage awaiting area, whereafter the full parts rack is unloaded onto the substage awaiting area, the AGV is moved to the substage empty area, an empty parts rack at the substage empty area is loaded onto the AGV, and the AGV is returned to the source of parts.
100091 According to a further feature of the invention methodology, the RAD
defines a tooling use area and, with a first model tooling in the tooling use area for use by the RAD, an AGV carrying a second model tooling is moved from the tooling management area to the RAD, the second model tooling is unloaded onto the RAD, and thereafter, following the completion of the first model vehicle production, the first model tooling is removed from the tooling use area, the second model tooling is moved to the tooling use area, the first model tooling is unloaded onto an AGV, and the AGV is returned to the tooling management area.
[0010] According to a further feature of the invention methodology, the movement path includes a first movement path portion extending from the tooling management area to a location proximate one side of the RAD and a second movement path portion extending from a location proximate an opposite side of the RAD to the tooling management area;
and the movement of the second model tooling from the tooling management area to the RAD is along the first movement path portion and the movement of the first model tooling to the tooling management area to the RAD is along the second movement path portion.
[0010a1 According to a further feature of the invention methodology, a modular assembly station apparatus for use in assembling motor vehicle components comprises a longitudinally extending scaffold structure having an independent and modular first and a second robot platform scaffold structures positioned on opposing sides of an assembly line, the first and second scaffold structures each including a top wall structure and support columns extending downwardly from the top wall structure to define an open working space below the top wall structure and a work area between the first and second scaffold structures laterally across the assembly line; at least one inverted robot connected to the top wall structure of at least one of the first and second robot platform scaffolds and extending downwardly from the top wall structure into the working space below the top wall structure laterally distant from the assembly line and working area; a modular flanking shelf positioned laterally outward from at least one of the first and second robot platform scaffold structures and in communication with the work space, the flanking shelf including support pillars extending upward from a ground support surface to elevate the flanking , shelf above the ground surface defining a transverse path of travel below the flanking shelf through the work space and in communication with the work area, the flanking shelf adapted to vertically support at least one vehicle component rack accessible by the at least one inverted robot; a conveyor positioned along the transverse path of travel for selectively transferring a plurality of different tooling linearly along the transverse path of travel to and from the work area; and a robot control device carried on the scaffold structure and operatively connected to the respective inverted robot, wherein on positioning of vehicle components in the working area along the assembly line, the inverted robot selectively articulates laterally into and out of the working area to conduct predetermined work on the vehicle components without using floor space in the working space.
[0010b] According to a further feature of the invention methodology, a modular assembly station apparatus for assembling motor vehicle components comprises a first modular longitudinally extending scaffold structure and a second modular longitudinally extending scaffold structure laterally spaced defining a work area therebetween having a first assembly line path of travel parallel to the longitudinal scaffold structures, each scaffold structure including a separate top wall structure and support columns extending downwardly from the top wall structure to define an open working space below the top wall structure between the support columns laterally spaced from the work area; a plurality of inverted robots supported on the top wall structure of each of the first and the second scaffold structures, each inverted robot extending downwardly from the top wall structure into the working space below the top wall structure, the plurality of robots longitudinally spaced from one another and laterally spaced from and longitudinally aligned parallel to the assembly line path; and robot control device carried on a respective scaffold structure and operatively connected to a plurality of robot control devices, each a respective inverted robot, wherein each of the inverted robots include a lower operative end adapted to selectively and independently extend in a direction transverse to the assembly line path from the work space into the work area to conduct work on the motor vehicle assembly components.
10010c] According to a further feature of the invention methodology, a motor vehicle body shop system comprises a body assembly line; a robotic welding assembly device positioned on the assembly line, the assembly device including a first and a second longitudinally extending scaffolding structure positioned on opposing sides of the assembly 3a line, each scaffolding structure is stationary and includes a top wall and a plurality of support columns to define a working space below the top wall and a work area positioned along the assembly line between the first and the second scaffolding structures, at least one inverted robot connected to at least one of the first and second scaffolding structure top wall extending downward into the working space; a source of parts positioned along a path of travel in communication with the welding assembly device; a first model tooling and a second model tooling in selective communication with the work area; at least one guided device for supporting at least one part moveable along the path of travel between at least the source of parts to a position adjacent to at least one of the first and the second scaffolding structures, wherein the at least one inverted robot transfers the at least one port from the guided device through the working space and into the work area; a tooling management area positioned along the path of travel distant from the welding assembly device and in communication with the welding assembly device, the tooling management area selectively housing the first model tooling and the second model tooling;
and a tool shuttle assembly positioned transverse to the assembly line through the working space in communication with the work area, the first and the second tooling selectively engaged with the tool shuttle to selectively move the first and the second tooling through the working space into the work area, wherein the at least one guided device selectively supports and reciprocally transfers the first and second model tooling from the tool management area along the path of travel to a position adjacent the first or the second scaffolding structure for engagement of the first and the second model tooling with the tool shuttle.
[0010d]
According to a further feature of the invention methodology, a motor vehicle body assembly system comprises a body assembly line; a robotic welding assembly device positioned on the assembly line, the assembly device including a first and a second longitudinally extending scaffolding structure positioned on opposing sides of the assembly line, each scaffolding structure is stationary and includes a top wall and a plurality of support columns to define a working space below the top wall and a work area positioned along the assembly line between the first and the second scaffolding structures, a plurality of inverted and upright robots positioned in working space of the first and the second scaffolding structures and selectively extendible into the work area; a source of parts positioned along a path of travel in communication with the welding assembly device; a tool management area for selectively housing a first model tooling and a second model 3b tooling, the tool management area positioned along the path of travel and in communication with the work area; and a plurality of guided devices selectively moveable along the path of travel between the tool management area, source of parts and welding assembly device for selective engagement, support and transfer of the first and second model tooling and parts for supporting at least one part moveable along the path of travel between at least the source of parts to a position adjacent to at least one of the first and the second scaffolding structures, wherein at least one the plurality of inverted or upright robots engage the at least one part and transfer the at least one part through the working space and into the work area.
[0010e] According to a further feature of the invention methodology, a method of managing a motor vehicle body shop assembly of the type including a body assembly line and a robotic welding assembly device positioned on the assembly line, the method comprises providing at least one self-contained automated guide vehicle adapted for independent movement about the assembly line, a source of parts remote from the assembly line, the source of parts including parts located on parts racks, a tooling management area remote from the assembly line, the tooling management area including first model tooling for use by the robotic welding assembly device to assemble a first motor vehicle model and second model tooling for use by the robotic welding assembly device to assemble a second motor vehicle model, a movement path for the at least one self-contained automated guide vehicle extending from the remote locations of the source of parts and the tooling management area to the robotic welding assembly device and returning to the source of parts and the tooling management area, and a positioning system for the at least one self-contained automated guide vehicle for selective movement along the movement path between the source of parts, the tooling management area, and the robotic welding assembly device; and utilizing the at least one self-contained automated guide vehicle to selectively deliver first model tooling and second model tooling to the robotic welding assembly device for use in respectively assembling the first motor vehicle model and the second motor vehicle model, return the first model tooling or second model tooling not in use to the tooling management area, and deliver full parts racks from the source of parts to the robotic welding assembly device and return empty parts racks to the source of parts.
1001011 According to a further feature of the invention methodology, a method of managing a motor vehicle body shop assembly of the type including a body assembly line 3c and a robotic welding assembly device positioned on the assembly line, the method comprises providing at least one automated guide vehicle, a source of parts located on parts racks, a tooling management area including first model tooling for use by the robotic welding assembly device to assemble a first motor vehicle model and second model tooling for use by the robotic welding assembly device to assemble a second motor vehicle model, means defining a movement path for the at least one self-contained automated guide vehicle extending from the source of parts and the tooling management area to the robotic welding assembly device and returning to the source of parts and the tooling management area, and a positioning system for the at least one self-contained automated guide vehicle for selective movement along the movement path between the source of parts, the tooling management area, and the robotic welding assembly device; utilizing the at least one self-contained automated guide vehicle to selectively deliver first model tooling and second model tooling to the robotic welding assembly device for use in respectively assembling the first motor vehicle model and the second motor vehicle model, return the first model tooling or second model tooling not in use to the tooling management area, and deliver full parts racks from the source of parts to the robotic welding assembly device and return empty parts racks to the source of parts; providing a staging area at the robotic welding assembly device including a plurality of substage areas arranged sequentially and proximate the movement path, the staging area including a substage awaiting area, a substage in-use area, and a substage empty area arranged sequentially along and proximate the movement path; and delivering parts racks to the staging area utilizing the at least one self-contained automated guide vehicle and thereafter moving the parts racks sequentially between the substage areas, wherein with a full first parts rack in the substage in-use area for use by the robotic welding assembly device, an empty second parts rack in the substage empty area, and a void in the substage awaiting area, an automated guide vehicle carrying a full third parts rack is moved from the source of parts to the staging area, the full third parts rack is loaded onto the substage awaiting area, the empty second parts rack is unloaded onto the automated guide vehicle, and the automated guide vehicle is returned to the source of parts.
[0010g] According to a further feature of the invention methodology, a method of managing a motor vehicle body shop assembly of the type including an assembly line and a robotic welding assembly device positioned on the line, the method comprises providing at least one automated guide vehicle, a source of parts located on parts racks, means defining 3d a movement path for the at least one automated guide vehicle extending from the source of parts to the robotic welding assembly device and returning to the source of parts, and a positioning system for the at least one automated guide vehicle for selective movement along the movement path; providing a staging area at the robotic welding assembly device including a plurality of substage areas arranged sequentially along and proximate the movement path, the staging area including a substage awaiting area, a substage in-use area, and a substage empty area arranged sequentially along and proximate the movement path;
and delivering a parts rack to the staging area utilizing the at least one automated guide vehicle and thereafter moving the parts rack sequentially between the substage areas, wherein with a full parts rack in the substage in-use area for use by the robotic welding assembly device, an empty rack in the substage empty area and a void in the substage awaiting area, an automated guide vehicle carrying a full parts rack is moved from the source of parts to the substage awaiting area, the full parts rack is unloaded onto the substage awaiting area, the empty parts rack is unloaded onto the automated guide vehicle, and the automated guide vehicle is returned to the source of parts.
Further features of the invention relate to systems and apparatus for carrying out the above-identified methodology features.
3e BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
[0013] Figure 1 is an overall layout plan of a welding body shop according to the invention;
[0014] Figure 2 is a partial end elevational view of the body shop of Figure 1;
[0015] Figure 3 is a fragmentary plan view of the body shop of Figure 1;
[0016] Figure 4 is a plan view of a portion of the body shop as shown in Figure 3;
[0017] Figure 5 is an end elevational view of a roller assembly utilized in the invention body shop;
[0018] Figure 6 is an end elevational view of a pallet assembly utilized in the invention body shop;
[0019] Figure 7 is a schematic perspective view of a portion of the welding body shop;
[0020] Figure 8 is a schematic plan view of the portion of the welding body shop seen in Fig. 7;
[0021] Figures 9-13 are sequential views illustrating a component parts delivery system according to the invention;
[0022] Figure 14 is a fragmentary perspective view of a tooling transfer apparatus;
[0023] Figure 15 is a fragmentary perspective view illustrating a trolley utilized in the tooling transfer apparatus of Figure 14; and [0024] Figures 16-21 are sequential views illustrating a tool exchange system methodology according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] The invention body shop 10 as seen in overview in Fig. 1 includes a material management area 12, a sub-assembly area 14, a main line area 16 and a tool management area 17. Material and work flow in Fig. 1 is essentially from right to left with provision for return movement and tooling exchange flow in Fig. 1 is essentially from left to right with provision for return movement. Material management area 12 will be seen to constitute a source of component parts for the welding operations.
[0026] In material management area 12, material arriving at loading dock 13 by rail 18 or semitrailers 20 is unloaded and stacked in dunnage containers whereafter it is removed from the dunnage containers, placed in parts racks 22, and, as needed, loaded onto Automatic Guided Vehicles (AGV) 24 for automatic battery powered movement down aisles 26 to selectively deliver the materials to sub assembly area 14 and main line area 16.
[0027] Sub assembly area 14 consists of six parallel rows of roller assemblies 28 arranged between respective aisles 26.
10028] Main line area 16 consists of six parallel rows of robotic welding assembly devices including three parallel rows of robotic roller assemblies 28 and three parallel rows of robotic pallet assemblies 30 arranged between the respective aisles 26.
[0029] Each robotic roller assembly 28 (Figs. 2, 3, 4, 5 and 9) comprises an open scaffold structure including a central tower structure 32, laterally spaced robot scaffold platform structures 34, and outboard flanking shelves 36a, 36b. Each robot scaffold platform structure 34 includes a top wall structure 34a and leg support structure 34b extending downwardly from the top wall structure 34a to define an open working space WS below the top wall structure. Each robot roller assembly 28 further includes robot controllers 38 mounted on robot top walls 34a, an upper overhead carrier 40, a lower overhead carrier 41, and a plurality of robots 42, all arranged in symmetrical alignment with a central assembly line 47. For example, three inverted robots 42 may be suspended from the top wall 34a of each robot platform structure for a total of six robots. The inverted robots are supported in longitudinally spaced relation on the top wall 34a of each scaffold structure and extend downwardly from the top wall into the working space WS
below the top wall. The laterally spaced scaffold structures 34 define a weld area WA
therebetween and the lower ends 42a of the inverted robots extend into the weld area WA
where the lower ends 42a of the inverted robots on one scaffold structure 34 may coact with the lower ends 42a of the inverted robots on the laterally adjacent scaffold structure 34 to perform welding or other operations on motor vehicle components positioned in the weld area WA.
100301 Further details of robotic roller assembly 28 may be seen in U.S.
Patent Nos.
6,799,673 and 6,564,440.
5a 100311 Each robotic pallet assembly 30 (Figs. 2, 3 and 6) comprises an open scaffold structure including laterally spaced robot platform structures 50, outer flanking shelves 52a, 52b, robot controllers 54 mounted on robot platform structures 50, a plurality of robots 56, and a lower central conveyor structure 58 carrying a pallet 60 arranged for powered movement along central assembly line 47. For example, three robots 56 may be suspended from the platform 50A of one robot platform structure and two robots 56 may extend upwardly from the floor 50B of each robot platform structure for a total of ten robots.
[0032] Further details of the robotic pallet assembly 30 may be seen in U.
S. Patent No. 6,948,227.
[0033] Tool management area 17 consists of a plurality of different model tooling for use by the robotic welding assembly devices to respectively produce various different motor vehicle models. For example, tool management area 17 may include tooling 17a, 17b, 17c, 17d, 17e and 17f to assist the robotic welding assemblies to respectively produce first, second, third, fourth, fifth and sixth motor vehicle models.
[0034] In overview, parts or the like arrive in dunnage via rail 18 or truck 20 to loading docks whereafter the parts are removed from the dunnage and loaded onto parts racks 22 whereafter, as needed, AGVs 24 receive the parts racks and travel to the left into the subassembly area 14 and the main line area 16. The material will be staged with a certain model or sequence of various models of the product line that is being assembled.
Some of the material will be upgraded in the subassembly area and then moved to the main line but in any event the material flow goes right to left. All of the main line rows are similar. The three on the bottom as seen as in Fig. 1 are roller assemblies 28 and the three on the top as seen in Fig. 1 are pallet assemblies 30. In general, the roller assemblies are utilized to build the geometric of the vehicle which is the underbody and body side left and body side right and the pallet assemblies are utilized to build the underbody with spot framing and with spot and body closure decking or assembly. All of the material comes in dunnage which is engineered dunnage and presents a required number of components at the point of use. The system does not use any conveyors nor does it utilize any manual operations or anything to pollute the main line assembly. Material shelves are provided on each side of the roller assemblies and the pallet assemblies. These shelves are utilized to supply materials or parts to each roller or pallet assembly and/or utilized to deliver tooling to each roller or pallet assembly to facilitate changeover to a different body style. The aisle between each row of assemblies includes a main body aisle as well as walkways flanking the main body aisle and adjacent to the material shelves of the assemblies. The AGVs 24 move along a movement path 25 which extends along each aisle and between each aisle and serves to totally interconnect the material management area 12, the subassembly area 14, the main line area 16, and the tooling management area 17. Path 25, as best seen in Figs. 7 and 8, may include a path portion 25a extending along one side of aligned roller assemblies 28 and a path portion 25b extending along an opposite side of the aligned assemblies.
[0035] With this movement path 25, AGVs may, as shown, at times be moving in side-by-side fashion with one AGV delivering parts or tooling in an upper aisle as seen in Fig.
1 and another AGV delivering parts or tooling in an adjacent lower aisle in Fig. 1. The material or tooling delivered by each AGV is delivered to the shelf structures of the roller or pallet assemblies whereafter the parts or tooling are moved to working in-use positions. This arrangement eliminates the necessity for people to be involved or for conveyors to be involved.
[0036] Each AGV 24 comprises a small vehicle that may be for example six feet wide and fifteen feet long with four wheels on the bottom and battery operated and includes a load/unload mechanism typically in the form of a forklift mechanism shown schematically at 24A. The AGVs go up and down the aisles just like a small car and are guided through a positioning system such as a GPS system. Each AGV has an implant positioning system so that each factory column has a transmitter and each AGV has a receiver that identifies the location of the AGV within the plant so that the precise location of the AGV
within the plant is always known. AGVs of this type are in common use in the automotive industry and have the ability to be guided through the factory, and perform load/unload functions, via a transmitter on the AGV. The system allows a batch build that specifically allows building one model and then plus one, plus one, plus one so that flexibility of the system is unlimited.
The system can build, for example, 15 models but can also build one at time.
The system can build one model for an hour and then one for five hours and then one for three hours and then one for nine hours and so forth. The key aspect of the system is engineered material flow.
The system utilizes modular tooling and engineered product flow and enables movement from parts to sub assembly to main lines or directly to main line with all the parts being delivered using AGVs to the point of use so that the system decouples people from the main line. There are no people on the main line because all material comes in to the main line in a dunnage or in some kind of wrapping system. Material is always brought to a line, these AGVs traveling basically right to left. Material flow is a one way street except the outside aisles provide return movement for the empty parts racks. This arrangement yields a generally circular movement of the AGVs with the AGVs moving down the top three aisles as seen in Fig. 1, turning right at the end of the aisle for passage to the upper aisle and the AGVs in the lower three aisles making a left turn as they move beyond the main line area for movement to the lower or outer aisle and movement back to the material management area to receive further parts and begin a new supply cycle. As noted the AGVs are powered and each has a battery. An AGV parking and charging area 70 is provided to allow the AGVs to park themselves into an electric receptacle and be charged. The AGVs thereby basically recharge themselves for a period of time and move back into operation.
[0037] The AGVs function not only to bring component parts to the various weld stations for welding on the assembly line but also function to exchange the tooling at the weld stations to effect motor vehicle model changeover.
[0038] The manner in which the AGVs function to deliver component parts to the weld stations is best seen in Figs. 7, 8, 9 and in sequential Figs. 9-13.
[00391 With respect to the delivery of components to a robotic roller assembly 28 and with particular reference to Figs. 9-13, a staging area 71 is provided on a shelf 36 of each assembly 28 including a substage waiting area 72, a substage in-use area 74, and a substage empty area 76 arranged sequentially along and proximate the adjacent portion of the movement path 25 of the AGV. With a full parts rack 22 positioned in the in-use area 74 for use by the robotic welding assembly, an empty rack 22 positioned in the empty area 76, and a void in the waiting area 72 (Fig. 10), the system operates to move an AGV 24 carrying a full parts rack 22 from the source of parts 12 to the staging area 71 (Fig. 11), unload the full parts rack 22 onto the waiting area 72, unload the empty parts rack 22 onto the AGV
24 (Fig. 12), and return the AGV 24 to the source of parts 12 (Fig. 13).
[0040] As seen, the movement of an AGV 24 canrying a full parts rack from the source of parts to the staging area initially comprises movement of the AGV to the substage waiting area (Fig. 11), whereafter the full parts rack is loaded onto the substage waiting area, the AGV is moved to the substage empty area (Fig. 12), the empty parts rack is loaded onto the AGV, and the AGV is returned to the source of parts (Fig. 13).
[0041] This system is further operative following depletion of the parts from the full parts rack 22 at the in-use area 74, to move the now empty parts rack 22 from the in-use area to the now empty empty substage 76 and move the full parts rack 22 at the waiting area 72 to the now empty in-use area 74 for use by the robotic welding device 28, whereafter the system is operative to again move an AGV 24 carrying a full parts rack 22 from the source of parts 12 to the staging area 71, unload the full parts rack 22 onto the waiting area 72, unload the empty parts rack 22 onto the AGV 24, and return the AGV 24 to the source of parts 12.
[0042] It will be understood that the loading of parts racks 22 onto the AGV and the unloading of parts racks from the AGV is accomplished utilizing the forklift mechanism 24a of the AGV; the movement of the parts racks between the substage areas 72, 74, 76, is accomplished using a robot 42 of the related robotic roller assembly 28; the movement of component parts from the parts rack at the substation in-use area 74 for use in forming the motor vehicle body structure is accomplished by a robot 42 of the related robotic roller assembly 28; and the actual welding of the component parts to form the motor vehicle body is also accomplished by a weld robot 42 of the related robot roller assembly.
[0043] It will further be understood that the above described component delivery procedure may be carried out utilizing either shelf 36a or opposite shelf 36b and it will be further understood that component parts in parts racks 22 are supplied to either shelf 50b, 50b of the robot pallet assemblies 30 by the AGVs in the same manner as described with respect to the robot roller assemblies.
[0044] With respect to the use of the AGVs to change tooling at a robotic assembly 28 or 30, and with particular reference to Figs. 14 and 15, a tooling shuttle assembly 80 is positioned transversely beneath the assembly 28. Assembly 80 includes a pair of parallel
100091 According to a further feature of the invention methodology, the RAD
defines a tooling use area and, with a first model tooling in the tooling use area for use by the RAD, an AGV carrying a second model tooling is moved from the tooling management area to the RAD, the second model tooling is unloaded onto the RAD, and thereafter, following the completion of the first model vehicle production, the first model tooling is removed from the tooling use area, the second model tooling is moved to the tooling use area, the first model tooling is unloaded onto an AGV, and the AGV is returned to the tooling management area.
[0010] According to a further feature of the invention methodology, the movement path includes a first movement path portion extending from the tooling management area to a location proximate one side of the RAD and a second movement path portion extending from a location proximate an opposite side of the RAD to the tooling management area;
and the movement of the second model tooling from the tooling management area to the RAD is along the first movement path portion and the movement of the first model tooling to the tooling management area to the RAD is along the second movement path portion.
[0010a1 According to a further feature of the invention methodology, a modular assembly station apparatus for use in assembling motor vehicle components comprises a longitudinally extending scaffold structure having an independent and modular first and a second robot platform scaffold structures positioned on opposing sides of an assembly line, the first and second scaffold structures each including a top wall structure and support columns extending downwardly from the top wall structure to define an open working space below the top wall structure and a work area between the first and second scaffold structures laterally across the assembly line; at least one inverted robot connected to the top wall structure of at least one of the first and second robot platform scaffolds and extending downwardly from the top wall structure into the working space below the top wall structure laterally distant from the assembly line and working area; a modular flanking shelf positioned laterally outward from at least one of the first and second robot platform scaffold structures and in communication with the work space, the flanking shelf including support pillars extending upward from a ground support surface to elevate the flanking , shelf above the ground surface defining a transverse path of travel below the flanking shelf through the work space and in communication with the work area, the flanking shelf adapted to vertically support at least one vehicle component rack accessible by the at least one inverted robot; a conveyor positioned along the transverse path of travel for selectively transferring a plurality of different tooling linearly along the transverse path of travel to and from the work area; and a robot control device carried on the scaffold structure and operatively connected to the respective inverted robot, wherein on positioning of vehicle components in the working area along the assembly line, the inverted robot selectively articulates laterally into and out of the working area to conduct predetermined work on the vehicle components without using floor space in the working space.
[0010b] According to a further feature of the invention methodology, a modular assembly station apparatus for assembling motor vehicle components comprises a first modular longitudinally extending scaffold structure and a second modular longitudinally extending scaffold structure laterally spaced defining a work area therebetween having a first assembly line path of travel parallel to the longitudinal scaffold structures, each scaffold structure including a separate top wall structure and support columns extending downwardly from the top wall structure to define an open working space below the top wall structure between the support columns laterally spaced from the work area; a plurality of inverted robots supported on the top wall structure of each of the first and the second scaffold structures, each inverted robot extending downwardly from the top wall structure into the working space below the top wall structure, the plurality of robots longitudinally spaced from one another and laterally spaced from and longitudinally aligned parallel to the assembly line path; and robot control device carried on a respective scaffold structure and operatively connected to a plurality of robot control devices, each a respective inverted robot, wherein each of the inverted robots include a lower operative end adapted to selectively and independently extend in a direction transverse to the assembly line path from the work space into the work area to conduct work on the motor vehicle assembly components.
10010c] According to a further feature of the invention methodology, a motor vehicle body shop system comprises a body assembly line; a robotic welding assembly device positioned on the assembly line, the assembly device including a first and a second longitudinally extending scaffolding structure positioned on opposing sides of the assembly 3a line, each scaffolding structure is stationary and includes a top wall and a plurality of support columns to define a working space below the top wall and a work area positioned along the assembly line between the first and the second scaffolding structures, at least one inverted robot connected to at least one of the first and second scaffolding structure top wall extending downward into the working space; a source of parts positioned along a path of travel in communication with the welding assembly device; a first model tooling and a second model tooling in selective communication with the work area; at least one guided device for supporting at least one part moveable along the path of travel between at least the source of parts to a position adjacent to at least one of the first and the second scaffolding structures, wherein the at least one inverted robot transfers the at least one port from the guided device through the working space and into the work area; a tooling management area positioned along the path of travel distant from the welding assembly device and in communication with the welding assembly device, the tooling management area selectively housing the first model tooling and the second model tooling;
and a tool shuttle assembly positioned transverse to the assembly line through the working space in communication with the work area, the first and the second tooling selectively engaged with the tool shuttle to selectively move the first and the second tooling through the working space into the work area, wherein the at least one guided device selectively supports and reciprocally transfers the first and second model tooling from the tool management area along the path of travel to a position adjacent the first or the second scaffolding structure for engagement of the first and the second model tooling with the tool shuttle.
[0010d]
According to a further feature of the invention methodology, a motor vehicle body assembly system comprises a body assembly line; a robotic welding assembly device positioned on the assembly line, the assembly device including a first and a second longitudinally extending scaffolding structure positioned on opposing sides of the assembly line, each scaffolding structure is stationary and includes a top wall and a plurality of support columns to define a working space below the top wall and a work area positioned along the assembly line between the first and the second scaffolding structures, a plurality of inverted and upright robots positioned in working space of the first and the second scaffolding structures and selectively extendible into the work area; a source of parts positioned along a path of travel in communication with the welding assembly device; a tool management area for selectively housing a first model tooling and a second model 3b tooling, the tool management area positioned along the path of travel and in communication with the work area; and a plurality of guided devices selectively moveable along the path of travel between the tool management area, source of parts and welding assembly device for selective engagement, support and transfer of the first and second model tooling and parts for supporting at least one part moveable along the path of travel between at least the source of parts to a position adjacent to at least one of the first and the second scaffolding structures, wherein at least one the plurality of inverted or upright robots engage the at least one part and transfer the at least one part through the working space and into the work area.
[0010e] According to a further feature of the invention methodology, a method of managing a motor vehicle body shop assembly of the type including a body assembly line and a robotic welding assembly device positioned on the assembly line, the method comprises providing at least one self-contained automated guide vehicle adapted for independent movement about the assembly line, a source of parts remote from the assembly line, the source of parts including parts located on parts racks, a tooling management area remote from the assembly line, the tooling management area including first model tooling for use by the robotic welding assembly device to assemble a first motor vehicle model and second model tooling for use by the robotic welding assembly device to assemble a second motor vehicle model, a movement path for the at least one self-contained automated guide vehicle extending from the remote locations of the source of parts and the tooling management area to the robotic welding assembly device and returning to the source of parts and the tooling management area, and a positioning system for the at least one self-contained automated guide vehicle for selective movement along the movement path between the source of parts, the tooling management area, and the robotic welding assembly device; and utilizing the at least one self-contained automated guide vehicle to selectively deliver first model tooling and second model tooling to the robotic welding assembly device for use in respectively assembling the first motor vehicle model and the second motor vehicle model, return the first model tooling or second model tooling not in use to the tooling management area, and deliver full parts racks from the source of parts to the robotic welding assembly device and return empty parts racks to the source of parts.
1001011 According to a further feature of the invention methodology, a method of managing a motor vehicle body shop assembly of the type including a body assembly line 3c and a robotic welding assembly device positioned on the assembly line, the method comprises providing at least one automated guide vehicle, a source of parts located on parts racks, a tooling management area including first model tooling for use by the robotic welding assembly device to assemble a first motor vehicle model and second model tooling for use by the robotic welding assembly device to assemble a second motor vehicle model, means defining a movement path for the at least one self-contained automated guide vehicle extending from the source of parts and the tooling management area to the robotic welding assembly device and returning to the source of parts and the tooling management area, and a positioning system for the at least one self-contained automated guide vehicle for selective movement along the movement path between the source of parts, the tooling management area, and the robotic welding assembly device; utilizing the at least one self-contained automated guide vehicle to selectively deliver first model tooling and second model tooling to the robotic welding assembly device for use in respectively assembling the first motor vehicle model and the second motor vehicle model, return the first model tooling or second model tooling not in use to the tooling management area, and deliver full parts racks from the source of parts to the robotic welding assembly device and return empty parts racks to the source of parts; providing a staging area at the robotic welding assembly device including a plurality of substage areas arranged sequentially and proximate the movement path, the staging area including a substage awaiting area, a substage in-use area, and a substage empty area arranged sequentially along and proximate the movement path; and delivering parts racks to the staging area utilizing the at least one self-contained automated guide vehicle and thereafter moving the parts racks sequentially between the substage areas, wherein with a full first parts rack in the substage in-use area for use by the robotic welding assembly device, an empty second parts rack in the substage empty area, and a void in the substage awaiting area, an automated guide vehicle carrying a full third parts rack is moved from the source of parts to the staging area, the full third parts rack is loaded onto the substage awaiting area, the empty second parts rack is unloaded onto the automated guide vehicle, and the automated guide vehicle is returned to the source of parts.
[0010g] According to a further feature of the invention methodology, a method of managing a motor vehicle body shop assembly of the type including an assembly line and a robotic welding assembly device positioned on the line, the method comprises providing at least one automated guide vehicle, a source of parts located on parts racks, means defining 3d a movement path for the at least one automated guide vehicle extending from the source of parts to the robotic welding assembly device and returning to the source of parts, and a positioning system for the at least one automated guide vehicle for selective movement along the movement path; providing a staging area at the robotic welding assembly device including a plurality of substage areas arranged sequentially along and proximate the movement path, the staging area including a substage awaiting area, a substage in-use area, and a substage empty area arranged sequentially along and proximate the movement path;
and delivering a parts rack to the staging area utilizing the at least one automated guide vehicle and thereafter moving the parts rack sequentially between the substage areas, wherein with a full parts rack in the substage in-use area for use by the robotic welding assembly device, an empty rack in the substage empty area and a void in the substage awaiting area, an automated guide vehicle carrying a full parts rack is moved from the source of parts to the substage awaiting area, the full parts rack is unloaded onto the substage awaiting area, the empty parts rack is unloaded onto the automated guide vehicle, and the automated guide vehicle is returned to the source of parts.
Further features of the invention relate to systems and apparatus for carrying out the above-identified methodology features.
3e BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
[0013] Figure 1 is an overall layout plan of a welding body shop according to the invention;
[0014] Figure 2 is a partial end elevational view of the body shop of Figure 1;
[0015] Figure 3 is a fragmentary plan view of the body shop of Figure 1;
[0016] Figure 4 is a plan view of a portion of the body shop as shown in Figure 3;
[0017] Figure 5 is an end elevational view of a roller assembly utilized in the invention body shop;
[0018] Figure 6 is an end elevational view of a pallet assembly utilized in the invention body shop;
[0019] Figure 7 is a schematic perspective view of a portion of the welding body shop;
[0020] Figure 8 is a schematic plan view of the portion of the welding body shop seen in Fig. 7;
[0021] Figures 9-13 are sequential views illustrating a component parts delivery system according to the invention;
[0022] Figure 14 is a fragmentary perspective view of a tooling transfer apparatus;
[0023] Figure 15 is a fragmentary perspective view illustrating a trolley utilized in the tooling transfer apparatus of Figure 14; and [0024] Figures 16-21 are sequential views illustrating a tool exchange system methodology according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] The invention body shop 10 as seen in overview in Fig. 1 includes a material management area 12, a sub-assembly area 14, a main line area 16 and a tool management area 17. Material and work flow in Fig. 1 is essentially from right to left with provision for return movement and tooling exchange flow in Fig. 1 is essentially from left to right with provision for return movement. Material management area 12 will be seen to constitute a source of component parts for the welding operations.
[0026] In material management area 12, material arriving at loading dock 13 by rail 18 or semitrailers 20 is unloaded and stacked in dunnage containers whereafter it is removed from the dunnage containers, placed in parts racks 22, and, as needed, loaded onto Automatic Guided Vehicles (AGV) 24 for automatic battery powered movement down aisles 26 to selectively deliver the materials to sub assembly area 14 and main line area 16.
[0027] Sub assembly area 14 consists of six parallel rows of roller assemblies 28 arranged between respective aisles 26.
10028] Main line area 16 consists of six parallel rows of robotic welding assembly devices including three parallel rows of robotic roller assemblies 28 and three parallel rows of robotic pallet assemblies 30 arranged between the respective aisles 26.
[0029] Each robotic roller assembly 28 (Figs. 2, 3, 4, 5 and 9) comprises an open scaffold structure including a central tower structure 32, laterally spaced robot scaffold platform structures 34, and outboard flanking shelves 36a, 36b. Each robot scaffold platform structure 34 includes a top wall structure 34a and leg support structure 34b extending downwardly from the top wall structure 34a to define an open working space WS below the top wall structure. Each robot roller assembly 28 further includes robot controllers 38 mounted on robot top walls 34a, an upper overhead carrier 40, a lower overhead carrier 41, and a plurality of robots 42, all arranged in symmetrical alignment with a central assembly line 47. For example, three inverted robots 42 may be suspended from the top wall 34a of each robot platform structure for a total of six robots. The inverted robots are supported in longitudinally spaced relation on the top wall 34a of each scaffold structure and extend downwardly from the top wall into the working space WS
below the top wall. The laterally spaced scaffold structures 34 define a weld area WA
therebetween and the lower ends 42a of the inverted robots extend into the weld area WA
where the lower ends 42a of the inverted robots on one scaffold structure 34 may coact with the lower ends 42a of the inverted robots on the laterally adjacent scaffold structure 34 to perform welding or other operations on motor vehicle components positioned in the weld area WA.
100301 Further details of robotic roller assembly 28 may be seen in U.S.
Patent Nos.
6,799,673 and 6,564,440.
5a 100311 Each robotic pallet assembly 30 (Figs. 2, 3 and 6) comprises an open scaffold structure including laterally spaced robot platform structures 50, outer flanking shelves 52a, 52b, robot controllers 54 mounted on robot platform structures 50, a plurality of robots 56, and a lower central conveyor structure 58 carrying a pallet 60 arranged for powered movement along central assembly line 47. For example, three robots 56 may be suspended from the platform 50A of one robot platform structure and two robots 56 may extend upwardly from the floor 50B of each robot platform structure for a total of ten robots.
[0032] Further details of the robotic pallet assembly 30 may be seen in U.
S. Patent No. 6,948,227.
[0033] Tool management area 17 consists of a plurality of different model tooling for use by the robotic welding assembly devices to respectively produce various different motor vehicle models. For example, tool management area 17 may include tooling 17a, 17b, 17c, 17d, 17e and 17f to assist the robotic welding assemblies to respectively produce first, second, third, fourth, fifth and sixth motor vehicle models.
[0034] In overview, parts or the like arrive in dunnage via rail 18 or truck 20 to loading docks whereafter the parts are removed from the dunnage and loaded onto parts racks 22 whereafter, as needed, AGVs 24 receive the parts racks and travel to the left into the subassembly area 14 and the main line area 16. The material will be staged with a certain model or sequence of various models of the product line that is being assembled.
Some of the material will be upgraded in the subassembly area and then moved to the main line but in any event the material flow goes right to left. All of the main line rows are similar. The three on the bottom as seen as in Fig. 1 are roller assemblies 28 and the three on the top as seen in Fig. 1 are pallet assemblies 30. In general, the roller assemblies are utilized to build the geometric of the vehicle which is the underbody and body side left and body side right and the pallet assemblies are utilized to build the underbody with spot framing and with spot and body closure decking or assembly. All of the material comes in dunnage which is engineered dunnage and presents a required number of components at the point of use. The system does not use any conveyors nor does it utilize any manual operations or anything to pollute the main line assembly. Material shelves are provided on each side of the roller assemblies and the pallet assemblies. These shelves are utilized to supply materials or parts to each roller or pallet assembly and/or utilized to deliver tooling to each roller or pallet assembly to facilitate changeover to a different body style. The aisle between each row of assemblies includes a main body aisle as well as walkways flanking the main body aisle and adjacent to the material shelves of the assemblies. The AGVs 24 move along a movement path 25 which extends along each aisle and between each aisle and serves to totally interconnect the material management area 12, the subassembly area 14, the main line area 16, and the tooling management area 17. Path 25, as best seen in Figs. 7 and 8, may include a path portion 25a extending along one side of aligned roller assemblies 28 and a path portion 25b extending along an opposite side of the aligned assemblies.
[0035] With this movement path 25, AGVs may, as shown, at times be moving in side-by-side fashion with one AGV delivering parts or tooling in an upper aisle as seen in Fig.
1 and another AGV delivering parts or tooling in an adjacent lower aisle in Fig. 1. The material or tooling delivered by each AGV is delivered to the shelf structures of the roller or pallet assemblies whereafter the parts or tooling are moved to working in-use positions. This arrangement eliminates the necessity for people to be involved or for conveyors to be involved.
[0036] Each AGV 24 comprises a small vehicle that may be for example six feet wide and fifteen feet long with four wheels on the bottom and battery operated and includes a load/unload mechanism typically in the form of a forklift mechanism shown schematically at 24A. The AGVs go up and down the aisles just like a small car and are guided through a positioning system such as a GPS system. Each AGV has an implant positioning system so that each factory column has a transmitter and each AGV has a receiver that identifies the location of the AGV within the plant so that the precise location of the AGV
within the plant is always known. AGVs of this type are in common use in the automotive industry and have the ability to be guided through the factory, and perform load/unload functions, via a transmitter on the AGV. The system allows a batch build that specifically allows building one model and then plus one, plus one, plus one so that flexibility of the system is unlimited.
The system can build, for example, 15 models but can also build one at time.
The system can build one model for an hour and then one for five hours and then one for three hours and then one for nine hours and so forth. The key aspect of the system is engineered material flow.
The system utilizes modular tooling and engineered product flow and enables movement from parts to sub assembly to main lines or directly to main line with all the parts being delivered using AGVs to the point of use so that the system decouples people from the main line. There are no people on the main line because all material comes in to the main line in a dunnage or in some kind of wrapping system. Material is always brought to a line, these AGVs traveling basically right to left. Material flow is a one way street except the outside aisles provide return movement for the empty parts racks. This arrangement yields a generally circular movement of the AGVs with the AGVs moving down the top three aisles as seen in Fig. 1, turning right at the end of the aisle for passage to the upper aisle and the AGVs in the lower three aisles making a left turn as they move beyond the main line area for movement to the lower or outer aisle and movement back to the material management area to receive further parts and begin a new supply cycle. As noted the AGVs are powered and each has a battery. An AGV parking and charging area 70 is provided to allow the AGVs to park themselves into an electric receptacle and be charged. The AGVs thereby basically recharge themselves for a period of time and move back into operation.
[0037] The AGVs function not only to bring component parts to the various weld stations for welding on the assembly line but also function to exchange the tooling at the weld stations to effect motor vehicle model changeover.
[0038] The manner in which the AGVs function to deliver component parts to the weld stations is best seen in Figs. 7, 8, 9 and in sequential Figs. 9-13.
[00391 With respect to the delivery of components to a robotic roller assembly 28 and with particular reference to Figs. 9-13, a staging area 71 is provided on a shelf 36 of each assembly 28 including a substage waiting area 72, a substage in-use area 74, and a substage empty area 76 arranged sequentially along and proximate the adjacent portion of the movement path 25 of the AGV. With a full parts rack 22 positioned in the in-use area 74 for use by the robotic welding assembly, an empty rack 22 positioned in the empty area 76, and a void in the waiting area 72 (Fig. 10), the system operates to move an AGV 24 carrying a full parts rack 22 from the source of parts 12 to the staging area 71 (Fig. 11), unload the full parts rack 22 onto the waiting area 72, unload the empty parts rack 22 onto the AGV
24 (Fig. 12), and return the AGV 24 to the source of parts 12 (Fig. 13).
[0040] As seen, the movement of an AGV 24 canrying a full parts rack from the source of parts to the staging area initially comprises movement of the AGV to the substage waiting area (Fig. 11), whereafter the full parts rack is loaded onto the substage waiting area, the AGV is moved to the substage empty area (Fig. 12), the empty parts rack is loaded onto the AGV, and the AGV is returned to the source of parts (Fig. 13).
[0041] This system is further operative following depletion of the parts from the full parts rack 22 at the in-use area 74, to move the now empty parts rack 22 from the in-use area to the now empty empty substage 76 and move the full parts rack 22 at the waiting area 72 to the now empty in-use area 74 for use by the robotic welding device 28, whereafter the system is operative to again move an AGV 24 carrying a full parts rack 22 from the source of parts 12 to the staging area 71, unload the full parts rack 22 onto the waiting area 72, unload the empty parts rack 22 onto the AGV 24, and return the AGV 24 to the source of parts 12.
[0042] It will be understood that the loading of parts racks 22 onto the AGV and the unloading of parts racks from the AGV is accomplished utilizing the forklift mechanism 24a of the AGV; the movement of the parts racks between the substage areas 72, 74, 76, is accomplished using a robot 42 of the related robotic roller assembly 28; the movement of component parts from the parts rack at the substation in-use area 74 for use in forming the motor vehicle body structure is accomplished by a robot 42 of the related robotic roller assembly 28; and the actual welding of the component parts to form the motor vehicle body is also accomplished by a weld robot 42 of the related robot roller assembly.
[0043] It will further be understood that the above described component delivery procedure may be carried out utilizing either shelf 36a or opposite shelf 36b and it will be further understood that component parts in parts racks 22 are supplied to either shelf 50b, 50b of the robot pallet assemblies 30 by the AGVs in the same manner as described with respect to the robot roller assemblies.
[0044] With respect to the use of the AGVs to change tooling at a robotic assembly 28 or 30, and with particular reference to Figs. 14 and 15, a tooling shuttle assembly 80 is positioned transversely beneath the assembly 28. Assembly 80 includes a pair of parallel
9 tracks 82, a pair of trolleys 84, 86 rollably positioned on the tracks, and a pallet 88, 90 carried on each trolley.
[0045] Tracks 82 will be seen to extend from a first end 82a proximate an AGV path portion 25a to a second end 82b proximate an AGV path portion 25b.
[0046] Each trolley 84, 86 includes an electric motor 92 together with suitable mechanisms operative to propel the trolleys along the tracks in response to energization of the motor.
[0047] Each pallet 88/40 is sized to be positioned on top of a respective trolley 84, 86.
[0048] The manner in which the shuttle assembly 80 is utilized to change tooling at assembly 28 is best seen in Fig. 16-21. Specifically, with initial reference to Fig. 16, with tooling 17a in place and in use at a tooling use area 78 positioned centrally of the robotic roller assembly 28 proximate the assembly line 47, an AGV 24 traveling on movement path 25a may be utilized to bring a tooling 17b to the roller assembly (Fig. 17) and load the tooling 17b into the trolley 86 positioned beneath the shelf 36a of the roller assembly utilizing the load/unload mechanism of the AGV (Fig. 18), whereafter, when tooling 17a usage is completed, trolley 84 is propelled to the left as seen in Fig. 19 to move the tooling 17a to a position beneath the shelf 36b on the opposite side of the roller assembly while trolley 86 is propelled to the left to move the tooling 17b to the tooling usage area 78 (Fig. 20), whereafter the tooling 17a may be loaded onto an AGV 24 traveling the movement path 25b on the other side of the assembly (Fig. 21) utilizing the AGV forklift mechanism 24a, whereafter the AGV
is operative to return the tooling 17a to the tooling management area 17.
[0049] During usage of tooling 17b, further tooling may be brought to the left side of the assembly 28, utilizing an AGV traveling on movement path 25b, whereafter the further tooling may be loaded onto trolley 84 whereafter, when the usage of tooling 17b is completed, trolley 86 may be moved to the right to allow loading of tooling 17b onto an positioned to the right of the assembly for return on movement path 25a to the tooling area whereafter trolley 84 may be moved to the tooling use area 78 to position the further tooling at the tooling use area for use in fabricating a further motor vehicle model.
[0050] It will be understood that the tooling provided to the robotic assembly in each case includes tooling specific to the motor vehicle model being assembled and may include, for example, clamps or end effector tooling which is utilized by the robots of the assembly to facilitate the welding operations to form the motor vehicle body or motor vehicle body subassembly.
[0051] In the overall operation of the system, AGVs 24 are continually picking up parts racks 22 from the material management area 12 and taking the parts racks to the main line 17 for use by the various assemblies 28/30 while different AGVs serve to change tooling at the various assemblies 28/30, at such times as a specific model production is terminated and a new model production is initiated. The invention system makes possible a tooling exchange time of between two to three minutes.
[0052] The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
[0045] Tracks 82 will be seen to extend from a first end 82a proximate an AGV path portion 25a to a second end 82b proximate an AGV path portion 25b.
[0046] Each trolley 84, 86 includes an electric motor 92 together with suitable mechanisms operative to propel the trolleys along the tracks in response to energization of the motor.
[0047] Each pallet 88/40 is sized to be positioned on top of a respective trolley 84, 86.
[0048] The manner in which the shuttle assembly 80 is utilized to change tooling at assembly 28 is best seen in Fig. 16-21. Specifically, with initial reference to Fig. 16, with tooling 17a in place and in use at a tooling use area 78 positioned centrally of the robotic roller assembly 28 proximate the assembly line 47, an AGV 24 traveling on movement path 25a may be utilized to bring a tooling 17b to the roller assembly (Fig. 17) and load the tooling 17b into the trolley 86 positioned beneath the shelf 36a of the roller assembly utilizing the load/unload mechanism of the AGV (Fig. 18), whereafter, when tooling 17a usage is completed, trolley 84 is propelled to the left as seen in Fig. 19 to move the tooling 17a to a position beneath the shelf 36b on the opposite side of the roller assembly while trolley 86 is propelled to the left to move the tooling 17b to the tooling usage area 78 (Fig. 20), whereafter the tooling 17a may be loaded onto an AGV 24 traveling the movement path 25b on the other side of the assembly (Fig. 21) utilizing the AGV forklift mechanism 24a, whereafter the AGV
is operative to return the tooling 17a to the tooling management area 17.
[0049] During usage of tooling 17b, further tooling may be brought to the left side of the assembly 28, utilizing an AGV traveling on movement path 25b, whereafter the further tooling may be loaded onto trolley 84 whereafter, when the usage of tooling 17b is completed, trolley 86 may be moved to the right to allow loading of tooling 17b onto an positioned to the right of the assembly for return on movement path 25a to the tooling area whereafter trolley 84 may be moved to the tooling use area 78 to position the further tooling at the tooling use area for use in fabricating a further motor vehicle model.
[0050] It will be understood that the tooling provided to the robotic assembly in each case includes tooling specific to the motor vehicle model being assembled and may include, for example, clamps or end effector tooling which is utilized by the robots of the assembly to facilitate the welding operations to form the motor vehicle body or motor vehicle body subassembly.
[0051] In the overall operation of the system, AGVs 24 are continually picking up parts racks 22 from the material management area 12 and taking the parts racks to the main line 17 for use by the various assemblies 28/30 while different AGVs serve to change tooling at the various assemblies 28/30, at such times as a specific model production is terminated and a new model production is initiated. The invention system makes possible a tooling exchange time of between two to three minutes.
[0052] The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
Claims (20)
1. A modular assembly station apparatus for use in assembling motor vehicle components comprising:
a longitudinally extending scaffold structure having an independent and modular first and a second robot platform scaffold structures positioned on opposing sides of an assembly line, the first and second scaffold structures each including a top wall structure and support columns extending downwardly from the top wall structure to define an open working space below the top wall structure and a work area between the first and second scaffold structures laterally across the assembly line;
at least one inverted robot connected to the top wall structure of at least one of the first and second robot platform scaffolds and extending downwardly from the top wall structure into the working space below the top wall structure laterally distant from the assembly line and working area;
a modular flanking shelf positioned laterally outward from at least one of the first and second robot platform scaffold structures and in communication with the work space, the flanking shelf including support pillars extending upward from a ground support surface to elevate the flanking shelf above the ground surface defining a transverse path of travel below the flanking shelf through the work space and in communication with the work area, the flanking shelf adapted to vertically support at least one vehicle component rack accessible by the at least one inverted robot;
a conveyor positioned along the transverse path of travel for selectively transferring a plurality of different tooling linearly along the transverse path of travel to and from the work area; and a robot control device carried on the scaffold structure and operatively connected to the respective inverted robot, wherein on positioning of vehicle components in the working area along the assembly line, the inverted robot selectively articulates laterally into and out of the working area to conduct predetermined work on the vehicle components without using floor space in the working space.
a longitudinally extending scaffold structure having an independent and modular first and a second robot platform scaffold structures positioned on opposing sides of an assembly line, the first and second scaffold structures each including a top wall structure and support columns extending downwardly from the top wall structure to define an open working space below the top wall structure and a work area between the first and second scaffold structures laterally across the assembly line;
at least one inverted robot connected to the top wall structure of at least one of the first and second robot platform scaffolds and extending downwardly from the top wall structure into the working space below the top wall structure laterally distant from the assembly line and working area;
a modular flanking shelf positioned laterally outward from at least one of the first and second robot platform scaffold structures and in communication with the work space, the flanking shelf including support pillars extending upward from a ground support surface to elevate the flanking shelf above the ground surface defining a transverse path of travel below the flanking shelf through the work space and in communication with the work area, the flanking shelf adapted to vertically support at least one vehicle component rack accessible by the at least one inverted robot;
a conveyor positioned along the transverse path of travel for selectively transferring a plurality of different tooling linearly along the transverse path of travel to and from the work area; and a robot control device carried on the scaffold structure and operatively connected to the respective inverted robot, wherein on positioning of vehicle components in the working area along the assembly line, the inverted robot selectively articulates laterally into and out of the working area to conduct predetermined work on the vehicle components without using floor space in the working space.
2. The apparatus of claim 1 further comprising a modular central tower structure positioned laterally between and connected to the first and the second robot platform scaffold structures and laterally spanning the assembly line, the modular central tower structure having a top wall partially defining the work area.
3. The apparatus of claim 2 further comprising:
a lower conveyor positioned along the assembly line; and a carrier connected to the lower conveyor for supporting the vehicle components, the carrier and lower conveyor adapted to selectively and successively move the components through the work area.
a lower conveyor positioned along the assembly line; and a carrier connected to the lower conveyor for supporting the vehicle components, the carrier and lower conveyor adapted to selectively and successively move the components through the work area.
4. The apparatus of any one of claims 1 to 3 wherein each of the at least one inverted robot on at least one of the first and the second robot platform scaffold structures further comprises three robots each connected to the respective top wall and positioned longitudinally apart along the respective robot platform scaffold structure substantially parallel to the assembly line, each inverted robot adapted to be independently movable with respect to the adjacent inverted robots.
5. The apparatus of any one of claims 1 to 4 wherein the work area is a weld area for welding of motor vehicle components together.
6. The apparatus of claim 1 further comprising a plurality of modular first and second robot platform scaffold structures sequentially positioned and connected end-to-end along the assembly line for assembling motor vehicle components, each modular robot platform scaffold structure adapted for assembling a different motor vehicle component at the respective work area.
7. The apparatus of claim 3, wherein the modular central tower structure further comprises:
an upper wall positioned vertically above the modular central tower structure top wall and work area; and upper support columns extending downward from the upper wall and connected to lower support columns, the upper wall and upper support columns defining an upper path of travel in communication with the assembly line for transport of the carrier above the work area and parallel to the assembly line.
an upper wall positioned vertically above the modular central tower structure top wall and work area; and upper support columns extending downward from the upper wall and connected to lower support columns, the upper wall and upper support columns defining an upper path of travel in communication with the assembly line for transport of the carrier above the work area and parallel to the assembly line.
8. The apparatus of claim 7, wherein the modular central tower structure further comprises an upper conveyor in communication with the assembly line and the lower conveyor for selected movement of the carrier from the lower conveyor to the upper conveyor for movement of the carrier along the upper path of travel.
9. The apparatus of any one of claims 1 to 8, wherein the modular flanking shelf further comprises a plurality of vehicle component rack stage areas sequentially and longitudinally positioned parallel to the assembly line, wherein the individual vehicle component racks are selectively moved by the at least one inverted robot in the adjacent robot platform scaffold structure between the vehicle component rack stage areas.
10. The apparatus of claim 1 wherein an elevated flanking shelf is positioned adjacent both of the first and the second robot platform scaffold structures, each elevated flanking shelf partially defining a portion of the transverse path of travel below the respective elevated flanking shelf, each portion of the transverse path having a respective conveyor for selected transfer of tooling along the respective transverse path of travel through each respected work space of the first and second robot platform scaffold structures and in communication with the work area.
11. The apparatus of any one of claims 1 to 10 further comprising at least one robot positioned below and in substantial lateral alignment with the inverted robot in the work space below the top wall of at least one of the first and second robot platform scaffold structures and connected to the ground support surface.
12. A modular assembly station apparatus for assembling motor vehicle components comprising:
a first modular longitudinally extending scaffold structure and a second modular longitudinally extending scaffold structure laterally spaced defining a work area therebetween having a first assembly line path of travel parallel to the longitudinal scaffold structures, each scaffold structure including a separate top wall structure and support columns extending downwardly from the top wall structure to define an open working space below the top wall structure between the support columns laterally spaced from the work area;
a plurality of inverted robots supported on the top wall structure of each of the first and the second scaffold structures, each inverted robot extending downwardly from the top wall structure into the working space below the top wall structure, the plurality of robots longitudinally spaced from one another and laterally spaced from and longitudinally aligned parallel to the assembly line path; and a robot control device carried on a respective scaffold structure and operatively connected to a plurality of robot control devices, each a respective inverted robot, wherein each of the inverted robots include a lower operative end adapted to selectively and independently extend in a direction transverse to the assembly line path from the work space into the work area to conduct work on the motor vehicle assembly components.
a first modular longitudinally extending scaffold structure and a second modular longitudinally extending scaffold structure laterally spaced defining a work area therebetween having a first assembly line path of travel parallel to the longitudinal scaffold structures, each scaffold structure including a separate top wall structure and support columns extending downwardly from the top wall structure to define an open working space below the top wall structure between the support columns laterally spaced from the work area;
a plurality of inverted robots supported on the top wall structure of each of the first and the second scaffold structures, each inverted robot extending downwardly from the top wall structure into the working space below the top wall structure, the plurality of robots longitudinally spaced from one another and laterally spaced from and longitudinally aligned parallel to the assembly line path; and a robot control device carried on a respective scaffold structure and operatively connected to a plurality of robot control devices, each a respective inverted robot, wherein each of the inverted robots include a lower operative end adapted to selectively and independently extend in a direction transverse to the assembly line path from the work space into the work area to conduct work on the motor vehicle assembly components.
13. An apparatus according to claim 12 wherein the plurality of inverted robot comprises three inverted robots.
14. An apparatus according to claim 12 or 13 wherein each robot control device is positioned above the top wall structure.
15. The apparatus of any one of claims 12 to 14 wherein the work area is a weld area for welding of motor vehicle components together.
16. The apparatus of any one of claims 12 to 15 further comprising:
a modular elevated central tower structure positioned laterally between and connecting to the first and the second scaffold structures, the central tower defining a second path of travel elevated above the first and the second scaffold top wall structures and aligned with the first path of travel; and a conveyor positioned to successively move the motor vehicle components along the first and the second paths of travel.
a modular elevated central tower structure positioned laterally between and connecting to the first and the second scaffold structures, the central tower defining a second path of travel elevated above the first and the second scaffold top wall structures and aligned with the first path of travel; and a conveyor positioned to successively move the motor vehicle components along the first and the second paths of travel.
17. The apparatus of claim 16 further comprising a plurality of modular first scaffold structures, second scaffold structures and modular central tower structures positioned end to end, each respective first scaffold structure, second scaffold structure and central tower adapted for assembling a different motor vehicle component at the respective work area.
18. The modular assembly station of claim 16 or 17 wherein the central tower structure further comprises:
support columns extending upward from a base; and an upper horizontal beam connected to distal ends of the support columns.
support columns extending upward from a base; and an upper horizontal beam connected to distal ends of the support columns.
19. The modular assembly station of any one of claims 16 to 18 further comprising one of a plurality of individual pallets or overhead carriers engaged with the conveyor for supporting the workpieces along the first and the second paths of travel.
20. The modular assembly station of any one of claims 12 to 19 further comprising:
at least one robot connected to a floor of an assembly plant within the working space defined by the scaffold structure and selectively extendible into the working area adapted to conduct work on the vehicle components.
at least one robot connected to a floor of an assembly plant within the working space defined by the scaffold structure and selectively extendible into the working area adapted to conduct work on the vehicle components.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
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| CA2904752A CA2904752C (en) | 2008-10-31 | 2009-03-19 | Robotic high density welding body shop |
| CA2904751A CA2904751C (en) | 2008-10-31 | 2009-03-19 | Robotic high density welding body shop |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US12/262,722 | 2008-10-31 | ||
| US12/262,722 US8201723B2 (en) | 2008-03-12 | 2008-10-31 | Robotic high density welding body shop |
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| CA2904752A Division CA2904752C (en) | 2008-10-31 | 2009-03-19 | Robotic high density welding body shop |
| CA2904751A Division CA2904751C (en) | 2008-10-31 | 2009-03-19 | Robotic high density welding body shop |
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| CA2659143A1 CA2659143A1 (en) | 2010-04-30 |
| CA2659143C true CA2659143C (en) | 2015-12-15 |
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| CA2659143A Active CA2659143C (en) | 2008-10-31 | 2009-03-19 | Robotic high density welding body shop |
| CA2904751A Active CA2904751C (en) | 2008-10-31 | 2009-03-19 | Robotic high density welding body shop |
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| CA2904751A Active CA2904751C (en) | 2008-10-31 | 2009-03-19 | Robotic high density welding body shop |
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| CA (3) | CA2904752C (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CA3008600C (en) | 2014-12-15 | 2022-09-13 | Comau Llc | Modular vehicle assembly system and method |
| DE202015106459U1 (en) * | 2015-11-27 | 2017-03-02 | Kuka Systems Gmbh | manufacturing facility |
| US10281898B2 (en) * | 2015-07-16 | 2019-05-07 | The Boeing Company | Method and system for controlling automated operations on a workpiece |
| PL3452391T3 (en) | 2016-05-06 | 2024-07-01 | Comau Llc | Inverted carrier lift device system |
| CN107838546A (en) * | 2017-11-20 | 2018-03-27 | 苏州凯尔博精密机械有限公司 | A kind of intelligent transport welding production line |
| CN109967904B (en) * | 2017-12-27 | 2022-03-29 | 中集车辆(集团)股份有限公司 | Automatic assembling and welding method for trailer |
| CN109814566B (en) * | 2019-02-01 | 2022-11-22 | 青岛港国际股份有限公司 | Automatic change pier AGV operation place and overhaul device and system |
| US11420853B2 (en) | 2019-10-03 | 2022-08-23 | Comau Llc | Assembly material logistics system and methods |
| MX2022014615A (en) | 2020-06-08 | 2023-01-04 | Comau Llc | Assembly material logistics system and methods. |
| CN113134692A (en) * | 2021-01-27 | 2021-07-20 | 安徽中科春谷激光产业技术研究院有限公司 | Automatic assembly welding device for train side wall and welding method thereof |
| CN113275799A (en) * | 2021-06-01 | 2021-08-20 | 东风柳州汽车有限公司 | Welding system for vehicle assembly |
| CN113385844A (en) * | 2021-06-04 | 2021-09-14 | 东风柳州汽车有限公司 | Welding method of automobile side wall assembly |
| CN113492292B (en) * | 2021-07-19 | 2023-03-24 | 中国第一汽车股份有限公司 | Welding jig based on AGV multi-vehicle type switches |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| IT1152517B (en) * | 1982-09-02 | 1987-01-07 | Rosa Gaetano Di | AUTOMATIC SYSTEM FOR ASSEMBLING AND WELDING OF VEHICLE BODIES |
| AU6194690A (en) * | 1990-03-14 | 1991-10-03 | Permaflex Company | Non-synchronous assembly system |
| US5347700A (en) * | 1992-03-19 | 1994-09-20 | Mazda Motor Corporation | Method of assembling vehicle parts |
| US20030037432A1 (en) * | 2001-08-21 | 2003-02-27 | Mcnamara Jeffrey S. | Automotive body component positioning method and apparatus |
| AU2003301536A1 (en) * | 2002-10-22 | 2004-05-13 | Daihatsu Motor Co., Ltd. | Method of assembling motor vehicle body |
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- 2009-03-19 CA CA2904752A patent/CA2904752C/en active Active
- 2009-03-19 CA CA2659143A patent/CA2659143C/en active Active
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Also Published As
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| CA2904751C (en) | 2017-02-14 |
| CN101722421B (en) | 2013-10-30 |
| CA2659143A1 (en) | 2010-04-30 |
| CA2904752C (en) | 2017-02-14 |
| CN101722421A (en) | 2010-06-09 |
| CA2904751A1 (en) | 2010-04-30 |
| CA2904752A1 (en) | 2010-04-30 |
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