IE970172A1 - Manufacturing equipment and process - Google Patents

Abstract

An assembly system comprising at least two workstations (3), a workspace (4) between each workstation (3), a pallet (5) mountable on and moveable between each workstation (3) across the workspace (4) and conveying means (34, 35) on each workstation (3) for supporting the pallet (5) on and conveying the pallet (5) between the workstations (3) such that the pallet (5) can be temporarily supported between the workstations (3) across the workspace (4). <Fig. 14 is to accompany Abstract>

Description

The invention relates to manufacturing equipment and to a process of manufacturing. More particularly, the invention relates to manufacturing equipment for use in the manufacture of furniture and to a process for the manufacture of furniture.

Manufacture of items requiring assembly, usually manual assembly, frequently requires transfer of the items from workstation to workstation where an assembly operation or the like is carried out on the item at each workstation.

An object of the invention is to improve the efficiency and convenience of the equipment and manufacturing process of the prior art.

According to the invention there is provided an assembly system comprising at least two workstations, a workspace between each workstation, a pallet mountable on and moveable between each workstation across the workspace and conveying means on each workstation for supporting the pallet on and conveying the pallet between the workstations such that the pallet can be temporarily supported between the workstations across the workspace. .,. . .’TT”.*”?”*'’ ’ , ’ Preferably, the assembly system further comprises a return track for returning the pallet to a first workstation following conveyance of the pallet between workstations .

More preferably, the workstation comprises a brake for locking the pallet in position on the workstation.

Advantageously, the conveying means comprises at least one sliding track for sliding the pallet across and between the workstations.

Suitably, the track comprises rollers. Preferably, the pallet is adapted to carry a storage container.

In a preferred embodiment the workstation comprises four upstanding legs having a sliding track mounted between each pair of legs.

Preferably, each sliding track is provided with carrying rollers for conveying the pallet.

More preferably, each sliding track is provided with two support rollers either side of the carrying rollers for supporting the pallet across the workspace.

Advantageously, the brake comprises a pedal actuated brake. Preferably, the pedal actuated brake comprises a pallet engaging means, the pallet engaging means being pivotally connected by a link arm to the brake pedal such that displacement of the pedal urges the pallet engaging means into engagement with the pallet.

More preferably, the pallet engaging means comprises a brake pad to urge the pallet against a sliding track.

Advantageously, the pallet comprises a frame having a top board mounted thereon.

In a preferred embodiment the return track comprises an upper track disposed above and in parallel with a lower track to support a pallet in a substantially vertical disposition.

Preferably, the upper track and the lower track comprise rollers for carrying the pallet.

More preferably, the axis of rotation of the lower rollers is perpendicular to the axis of rotation of the upper rollers, the axis of rotation of the upper rollers being along a horizontal axis and the axis of rotation of the lower rollers being along a vertical axis such that the pallet is mountable on the upper rollers and slidable against the lower rollers.

Most preferably, the upper and lower tracks of the return track are inclined in parallel longitudinally downwards from the last workstation to the first workstation.

Advantageously, the return track comprises stop means to hold the pallets on the return track.

Preferably, the stop means comprises a gate biased against the upper track of the return track.

The invention also provides a process for the manufacture of an article along a production line comprising at least two workstations having a workspace therebetween, mounting a pallet on a first workstation, - carrying out a first operating step on an item on the pallet, conveying the pallet with the article from the first workstation to a second workstation across the workspace, - the pallet being supportable by the workstations between the first and second workstations, effecting a second operating step at the second workstation, and the pallet and the article being accessible from between the workstations, during each operating step.

Preferably, the operating steps comprises assembly steps .

More preferably, the pallet is locked into position on the workstation during assembly.

Suitably, the pallet is conveyed on rollers mounted on the workstations.

Advantageously, the rollers support the pallet across 10 the workspace.

Preferably, the assembled article is removed from the pallet following assembly.

More preferably, the pallet is removed from the final workstation following assembly.

Advantageously, the pallet is returned to the first workstation following assembly along a return track.

Preferably, the pallet is slid along the return track.

Advantageously, the return track is inclined towards |E 970172 the first workstation.

Most preferably, the article to be manufactured is an article of furniture.

The invention also extends to an article of furniture whenever manufactured by a process according to the invention.

The invention will now be described having regard to the accompanying drawings, in which: Fig. 1 is a side elevation of a production line, series of workstations and pallet return track in accordance with the invention with the direction of movement of the pallets on the series of workstations and the pallet return track being indicated by arrows; Fig. 2 is a top plan view of the production line, series of workstations and pallet return track of Fig. 1 with furniture under construction being positioned on the pallets and the direction of movement of the pallets on the workstations and the pallet return track being indicated by arrows; Fig. 3 is a perspective view from above of a workstation in accordance with the invention with no pallet thereon; Fig. 4 is a side elevation of the workstation of Fig. 3 with the pedal brake located towards the rear of the workstation; Fig. 5 is a side elevation of the top portion of the workstation of Fig. 4 with a pallet mounted on the workstation and the direction of movement of the pallet on the workstation being indicated by an 10 arrow; Fig. 6 is a side elevation of the pallet sliding track of the workstation with no pallet mounted thereon; Fig. 7 is a side elevation of the pallet sliding 15 track of Fig. 6 with a pallet shown in cross-section mounted on the workstation, the direction of movement of the pallet being indicated by an arrow; Fig. 8 is a top plan view of a pallet in accordance with the invention; Fig. 9 is a rear plan view of the pallet of Fig. 8 showing the pallet frame; Fig. 10 is an end elevation of the pallet of Fig. 9; Fig. 11 is an end elevation of the pallet of Fig. 9 with a storage box mounted on the pallet frame; Fig. 12 is a side elevation of the pallet in an upright position with the storage box mounted on the pallet frame; Fig. 13 is a perspective partially cut-away view of the pallet return track and workstation pallet sliding track engaging means of the pallet frame of Fig· 9; Fig. 14 is a perspective view of a first complete and a second partially cut-away workstation of the invention with a first pallet mounted on the first workstation sliding track and a second pallet disposed in the workspace between the first and second workstations, the second pallet being provided with a storage box mounted on the pallet frame; Fig. 15 is a rear elevation of a workstation having a pallet with storage box mounted on the sliding track; Fig. 16 is a partially cut-away rear elevation of the pallet return track having a pallet suspended therefrom; Fig. 17 is a partial cross-sectional view through a top portion of a pallet mounted on the pallet return track with the pallet frame engaging the upper track of the pallet return track; Fig. 18 is a partially cut-away upper perspective view of a lower portion of the pallet frame mounted on the pallet return track; Fig. 19 is a partially cut-away upper perspective view of the pallet-stop of the upper track of the pallet return track; Fig. 20 is a partial cross-section through the pedal brake of the workstation of Fig. 4; Fig. 21 is an end elevation of the pedal brake of Fig. 20 adjacent a roller and pallet frame; Fig. 22 is a schematic representation of the pedal brake mechanism in the off-position, and Fig. 23 is a schematic representation of the pedal brake mechanism of Fig. 22 in the on-position, for engaging a pallet.

As shown in Fig. 1, a production line 1 according to the invention is made up of a series 2 of spaced apart individual workstations 3. The workstations 3 are spaced apart by work areas 4 intermediate the workstations 3 of the series 2 which facilitate access to the area between workstations 3.

A pallet 5 is mounted on a first workstation 3 in the series 2 and is slidable onto the other workstations 3 in the series 2 in the direction indicated by the arrow. The pallet 5 is slidable across the work area 4 between the first and second workstations 3 as shown by the pallet 5 mounted across the work area 4 between the second and third workstations 3. Therefore, the pallets 5 are slidable in the direction of the arrow from left to right in the figure from workstation to workstation 3 across the work areas 4 of the production line 1. The pallets 5 slide on rollers (not shown) which shall be described more fully below.

An elongate pallet return track 6 is disposed in parallel with the production line 1.

Pallets 5 having been slid to the end of the production line 1 from workstation 3 to workstation 3 are removed from the final workstation and mounted in a substantially vertical orientation on the pallet return track 6 and can be slidably returned in the direction shown by the arrows to the first workstation 3 of the production line 1 to provide a continuous pallet recirculation mechanism. The pallet return track 6 is disposed at an incline such that the pallet return track 6 is at a higher level at the end of the pallet return track remote from the first workstation 3.

The pallet return track 6 is made up of an upper track 7 and a parallel lower track 8 having a series of upper and lower rollers 9 and 10, respectively, mounted thereon. A pallet 5 is mounted in a substantially vertical orientation from the upper track 7 and slides on the upper and lower rollers 9 and 10 generally in the direction of the arrow to the first workstation 3 of the production line 1. The pallet return track 6 is described more fully below in relation to Figs. 16 to .

A support rail 11 is suspended above the production line 1. Air hoses 12 are in turn suspended from the support rail 11 and terminate at air nozzles 13. The air nozzles 13 can be attached to hand portable pneumatic staple guns (not shown) which can be used at each workstation 3 below the air nozzles 13 to assemble furniture .

Fig. 2 shows a top plan view of the production line 1, series 2 of workstations and pallet return track 6 of Fig. 1. As shown in the drawing, a pallet 5 is mounted on the first workstation 3 of the production line 1 while a second pallet 5 is mounted between the second and third workstations 3 of the production line to bridge the work area 4 between the workstations 3 of the series 2. An item of furniture 14 is located on the first pallet 5 at the first workstation 3. The item of furniture 14 has a portion 15 which is not covered with fabric indicated by parallel lines while a fabric covered portion 16 of the item of furniture 14 is also shown.

As the item of furniture 14 on the pallet 5 is moved in the direction of the arrow along the production line 1, a fabric covering operation is carried out on the item 14 such that the area of the uncovered portion 15 decreases and the area of the covered portion 16 increases. The completely covered item of furniture 14, is shown on the pallet 5 at the final workstation 3 in the series 2.

The pallet return track 6 is also shown in Fig. 2. As shown in the drawing, the pallets 5 are mounted in a substantially vertical or upright orientation from the upper track 7 of the pallet return track 6.

Figs. 3 to 7 show an individual workstation in more detail. As shown in the drawings, a workstation 3 is made up of four upstanding corner posts or legs 17, 18, and 20 which define the area of the workstation 3.

Each leg 17, 18, 19 and 20 extends upwards from a foot plate 21. Each foot plate 21 is securely bolted to a floor surface by a bolt 22.

The workstation 3 has a front end 23, a rear end 24, a first side 25 adjacent the pallet return track 6 and an opposite side 26. The legs 17, 18, 19 and 20 have an L-shaped cross-section with the inner faces of the Lshaped cross-section disposed inwards. A transverse side bar 27 extends between the legs 17 and 18, and 19 and 20, respectively. The two transverse side bars 27 are arranged in parallel adjacent to and above the foot plates 21 of the legs 17, 18, 19 and 20. The transverse side bars 27 are also formed from a material having an L-shaped cross-section. The transverse side bars 27 are adapted to receive a storage shelf 28 (see Fig. 14) which is mounted between the legs 17, 18, 19 and 20 and the transverse bars 27. The storage shelf 28 is shown in Fig. 14.

At their free ends remote from the foot plate 21, a pallet track 29 extends between the legs 17 and 18, and 19 and 20, respectively, to carry pallets 5 from the rear end 24 to the front end 23 of the workstation 3.

The pallet tracks 29 are oriented perpendicular to the transverse bars 27. Each pallet track 29 is made up of an elongate support bar 30 having U-shaped cross5 section to define an upper flange 31, a lower flange 32 and an inner face 33 between the upper and lower flanges 31 and 32 but oriented away from the flanges 31 and 32.

The workstation 3 is further provided with a series of 10 diagonally oriented support bars 84 which extend between the pallet track 29, the legs 17, 18, 19 and 20 and the transverse bars 27.

The inner face 33 is disposed inwards towards the table workstation area and is provided with a series of rollers 34 arranged between two support rollers 35 of greater size than the rollers 34 and mounted at each end of the inner face 33 of the support bar.

A pallet 5 can slide on the rollers 34 and 35. The support rollers 35 support the weight of a pallet and any items thereon during transfer of a pallet 5 from workstation to workstation 3 across the work area 4.

As shown in Fig. 4, the workstation 3 is provided with a pedal brake 36 adjacent the leg 17 at the rear end 24 of the workstation 3. The pedal brake 36 is made up of a foot pedal 37 and a braking mechanism 38. The pedal brake 36 can lock a pallet 5 in position on a workstation 3. The pedal brake 36 is more fully described in relation to Figs. 20 to 23 below.

Fig. 5 shows a storage container 39 suspended from the pallet 5 mounted on the rollers 34 of the workstation 3. The container 39 and the method of mounting the storage container 39 from the pallet 5 will be described more fully below.

Figs. 8 to 13 show a pallet 5 of the invention in more detail. More particularly, Fig. 8 shows a top plan view of the pallet 5, Fig. 9 a bottom plan view of the pallet 5, Fig. 10 a front elevation of the pallet 5, Fig. 11 a pallet 5 with a storage box 39 suspended therefrom, Fig. 12 a side elevation of the pallet 5 with the storage box 39 attached thereto while Fig. 13 shows a perspective view of a detail of the pallet 5 illustrating engagement mechanisms 40 of the pallet 5.

As shown in Figs. 8 to 13 the pallet 5 is made up of a substantially rectangular top board 41 mounted on a support frame 42.

The support frame 42 is made up of a front bar 43, a rear bar 44 and two side bars 45 and 46 arranged to define the substantially rectangular support frame 42. The top board 41 is mounted on the front and rear bars and 44 while the side bars 45 and 46 are attached to the underside of the front and rear bars 43 and 44.

An intermediate support bar 47 corresponding to the dimensions of the side bars 45 and 46 is positioned between the side bars 45 and 46 and the top board 41. Mounting bolts 48 extend through the side bars 45 and 46 and the support bars 47 and into the top board 41 to secure the top board 41 to the frame 42.

The support frame 42 is further provided with two spaced apart storage box bars 49 and 50 disposed between the side bars 45 and 46 and which extend between front and rear bars 43 and 44 parallel to the side bars 45 and 46. The storage box bars 49 and 50, are of similar construction to the side bars 45 and 46 and a support bar 51 similar to the support bar 47 is disposed between the storage box bars 49 and 50 and the top surface 41. Securing bolts 52 extend through the storage box bars 49 and 50 and the support bar 51 into the top board 41 to secure the storage box bars 49 and 50 in position.

The side bars 45 and 46 of the frame 42 project or IE 9701/2 extend beyond the front bar 43 to define two bridging bars 53 and 54, respectively. Similarly, the side bars 45 and 46 project, albeit to a lesser degree, beyond the rear bar 44. The bridging bars 53 and 54 serve to bridge the work area 4 during transfer of a pallet 5 across the work areas 4 between workstations. The bridging bars are each provided with rubber stoppers 61 at their free ends. Similarly, the side bars 45 and 46 are provided with rubber stoppers at their ends adjacent the rear bar 44. This is more fully described below.

The storage box bars 49 and 50 are each provided with an inwardly oriented flange 55 and 56 at the surface remote from the top board 41. The flanges 55 and 56 extend towards one another to define two support channels 57 and 58, between the flanges 51 and 52, the storage box bars 49 and 50 and the top board 41. The support channels 57 and 58 can receive the lips 59 of a storage box 39 to support the storage box 39 between the storage box bars 49 and 50 as shown in Fig. 11. Furthermore, as shown in Fig. 12 the rear bar 44 of the support frame 42 serves as an abutment for the storage box 39 to prevent the storage box 39 from escaping from the support channels 57 and 58 when the pallet 5 is oriented in a vertical position as shown in Fig. 12.

IE 970^72 As shown in Figs. 9 and 13, the front and rear bars 43 and 44 are provided with hooking arms 60 at each end. The hooking arms 60 are oriented downwards away from the top board 41. The hooking arms 60 serve as guide means to guide the pallet 5 along the path defined by the pallet track 29 of each workstation 3 and to prevent the pallet 5 from becoming detached from the pallet track 29. In addition, the hooking arm 60 serves as engagement means for mounting the pallet 5 on the return track 6 as will be described more fully below in relation to Figs. 16 to 19.

Fig. 14 more clearly describes the arrangement of the pallet 5 on the workstation 3. As shown in the drawing, first and second pallets 5 are mounted on a first workstation 3 and between said first workstation and a second workstation 3, respectively. The second pallet 5 has a storage box 39 mounted in the storage box support channels 57 and 58 as previously described. As shown in the drawings, the side bars 45 and 46 of each pallet 5 are supported on and slidable along the track rollers 34 and support rollers 35 of the pallet track 29 on the workstation 3. As shown in the drawing, the bridging bars 53 and 54 define the leading edge of the pallet 5 during transfer of the pallet from the first workstation 3 to the second workstation 3 so that the bridging bars 53 and 54 make initial contact with the support rollers 35. The bars 53 and 54 on a first pallet 5 abut the second pallet 5 at their rubber stoppers 61 to urge the second pallet 5 forwards along the rollers 34 and support rollers 35 as shown in Fig. 14.

Fig. 15 shows a rear elevation of a workstation 3 having a pallet 5 mounted on the rollers 34 and 35 of the support bars 30. A storage box 39 is mounted in the support channels 57 and 58 of the support frame 42.

As shown in the drawing, the inwardly oriented flanges 55 and 56 of the storage box bars 49 and 50 support the storage box 39 at the lips 59.

The side bars 45 and 46 are mounted in sliding engagement on the rollers 34 and 35, while the free ends of the hooking arms 60 at either end of the front and rear bars 43 and 44 travel in the U defined by the outwardly oriented upper and lower flanges 31 and 32 of the support bar 30. The upper flange 31 overlaps with the hooking arm 60 to prevent the pallet 5 from 20 disengaging the workstation 3. As shown in the drawing the pedal brake 36 is located adjacent the rear leg 17 of the workstation 3. The brake is made up of a foot pedal 37 and a braking mechanism 38 as previously described. The braking mechanism is adapted to urge a brake plate 62 against the internal face of the side bar 45. Frictional engagement of the brake plate 62 with the side bar 45 of the support frame 42 prevents movement of the pallet on the rollers 34 and 35. Operation of the pedal brake 36 shall be more fully explained in relation to Figs. to 23 below.

Figs. 16 to 19 describe the structure of the return track 6 and the method of mounting of the pallet 5 on the pallet return track 6. Fig. 16 is a rear elevation of the pallet return track 6 having the pallet 5 suspended therefrom in a substantially vertical orientation. However, as shown in the drawing, the pallet 5 is disposed at an angle to the vertical axis so that the pallet 5 is inclined against the return track 6.

The return track 6 is made up of a series of vertically oriented support legs 63 upstanding from a series of foot plates 21 similar to the foot plates 21 of the workstations 3. The foot plates 21 are secured to a floor by securing bolts 22.

The return track 6 has an upper track 7 and a lower track 8 disposed substantially transverse to the vertical axis of the legs 63 which extend the length of it 970172 the return track 6. The upper and lower tracks 7 and 8 are inclined off the horizontal to define an incline or slope along the length of the return track 6 as shown in Fig. 1. The upper track 7 is provided with upper rollers 9 similar to the rollers 34 of the workstation and having their rotational axis oriented horizontally such that the rollers rotate in a vertical plane. The upper rollers 9 enjoy a sliding relationship with either of the side bars 45 and 46 of the support frame 42 of the pallet 5 when a pallet is mounted vertically on the return track 6. As shown in the drawing, the upper rollers 9 make contact with the side bars 45 and 46 at the face of the side bar 45 and disposed inwards towards the storage box bars 49 and 50.

The lower track 8 of the return track 6 is also provided with lower rollers 10. The lower rollers 10 are mounted to the underside of the lower track 8 with the rotational axis oriented perpendicular to the axis of the upper rollers 10 (in a vertical axis) such that the rollers 10 rotate in a horizontal plane perpendicular to the plane of rotation of the upper rollers 9. Accordingly, as the side bars 45 and 46 are mounted on the upper rollers 9 but slide against the lower rollers 10 the pallet 5 is urged outwards at the lower rollers 10 such that the pallet 5 is inclined or tilted on the return track 6. The pallet 5 makes contact with the lower rollers 10 at the side bar 46 and 47 of the support frame 42 and enjoys a sliding relationship with the lower rollers 10 so that the pallet 5 travels along the return track 6 and is suspended on the return track 6 at the side bars 46 and .

The return track 6 is further provided with a guiding/holding rail 64 adjacent to and parallel with the upper track 7 which holds the pallet 5 on the return track 6. The guiding/holding rail 64 is supported by a series of mounting brackets 85 which extend between the free end of the legs 63 and the upper surface of the guiding/holding rail 64. The guiding/holding rail 64 is made up of an inverted Lshaped bar 65 which extends the length of the return track 6. The L-shaped bar 65 has a top flange 66 and a side flange 67 perpendicular to the top flange 66 and oriented along a vertical axis. In use, the pallet 5 is mounted on the return track 6 by orienting the pallet 5 such that the side bars 45 and 46 are parallel to the upper and lower tracks 7 and 8, urging the pallet 5 upwards and inwards so that the side bar 45 rests on the upper rollers 9 and the hooking arm 60 is inserted behind the side flange 67. Accordingly, the pallet 5 is guided and held in position by the guiding/holding rail 64 so that the pallet will not fall from the return track 6 and is removed from the return track 6 by lifting and lowering the pallet 5 to disengage the pallet from the upper and lower rollers 9 and 10, respectively.

It should be noted that the pallet 5 rests securely on the rollers 9 and 10 due to the relative orientations of the upper and lower rollers 9 and 10 as previously described.

Fig. 19 shows a partially cut-away upper perspective view of an end portion of the guiding/holding rail 64. The end portion of the guiding/holding rail 64 is inclined towards the lower end of the inclined return track 6 and is provided with a stopper mechanism 67 to hold the pallet 5 on the return track 6 to prevent the pallet 5 from accidentally sliding from the return track 6. As shown in the drawing, the stopper mechanism 67 is made up of a hinged gate 68 disposed transversely to the L-shape bar 65. A mounting plate 69 is mounted over the top flange 66 of the guiding/holding rail 64. The gate 68 is hingedly connected to the mounting plate 69 and is biased against the free end of the guiding/holding rail 64 by a return spring 71 which extends between the free end of the gate 68 and the free end of the mounting plate 69. Accordingly, a pallet is prevented from sliding from the return track 6 by the gate 68 but can be urged through the gate 68 against the bias of the spring 71 if desired. Following exit of a pallet 5 through the gate 68 the gate 68 returns to its original position against the free end of the guiding/holding rail 64.

Fig. 20 shows a partial cross-section/side elevation through the pedal brake 36 while Fig. 21 shows an end elevation of the pedal brake 36 adjacent the rear leg 17 of the workstation 3. A pallet 5 is mounted on the rollers 34 and 35 of the workstation 3. Figs. 22 and 23 show schematic representations of the pedal brake 36 mechanism disengaged and engaged respectively with a pallet 5 to prevent movement of the pallet on the rollers 34 and 35.

As shown in the drawings, the pedal brake 36 is made up of the foot pedal 37 adjacent the foot plate 21 of the leg 17.

The foot pedal 37 is pivotally attached to the transverse side bar 27 of the workstation 3 at a pivot point 72 disposed midway along the length of the foot pedal 37. A link arm 73 extends upwards from a free end of the foot pedal 37 to a cross arm 74. The cross arm 74 is made up of two separated but parallel bars 75 ϊ. and 76 having a space 77 therebetween. The cross arm is oriented substantially diagonally to the link arm 73. The link arm 73 is pivotally attached at its first end to the foot pedal 37 at the pivot pin 86 at the free end of the foot pedal adjacent the leg 17 and at its second end to the cross arm 74. The cross arm 74 is in turn pivotally attached to the upstanding leg 17 at the pivot pin 86 at its upper free end. The bars 75 and 76 are pivotally bolted either side of the leg 17 and are provided with end bolts 78 and 79 in parallel at the end remote from the leg 17. Intermediate the end bolts 78 and 79 and the leg bolt 80, the link arm 73 is pivotally bolted between the bars 75 and 76 of the cross arm 74 at the pivot pin 86.

A brake arm 81 extends upwards from the gap 77 between the bar intermediate the bolts 78 and 79 and terminates at the brake plate 62. The brake arm 81 is suspended between the bolts 78, 79 and the pivot pin 86 in the space 77 by a bracket 82 mounted on the internal face of the support bar 30 adjacent the rollers 34. The brake arm 81 is pivotally mounted on the mounting bracket 82 with bolts 83 as shown in Figs. 22 and 23. The elongate brake arm 81 is located between the bars and 76 such that it travels over the pivot pin 80 and rides under the bolts 78 and 79. In order to operate the pedal brake 36, the foot pedal 37 is 7 Ο < 7 rj displaced downwards as shown in Fig. 23 about the pivot pin 72 such that the link arm 73 is displaced upwards at the pivot pin 87 and the cross arm 74 urged upwards to force the bolts 78 against the brake arm 81 which moves towards the support bar 30. The brake plate 62 therefore engages the internal face of the side bar 45 of the pallet 5 to prevent movement of the pallet on the rollers 34 and 35.

The brake is released by depressing the foot pedal 37 10 on the opposite side of the pivot pin 72 as shown in Fig. 22 to reverse the process described above and to release the pallet 5.

In use, a production line 1 as previously described can be used to manufacture items of furniture, for example, a sofa. A pallet 5 is mounted on the first workstation 3 in a series 2 of workstations of a production line 1. A storage container containing items to be used in the manufacture of the item of furniture is then mounted in the support channels 57 and 58 of the frame 42 of the pallet 5.

For example, in the manufacture of a three piece suite of furniture, six sections of fabric corresponding to the six arms of a three piece suite of furniture could be placed in the storage container 39. In addition, other components necessary to assemble a three piece suite of furniture could also be placed in the storage container 39. Generally, an operative at each workstation has an allotted task such as the aforementioned application of fabric to the arms of a sofa, armchair, etc. Accordingly, where the function of an operative at the first workstation 3 is the application of the fabric to the arms of each item of the three-piece suite of furniture, that operative removes the items from the storage container 39 which it is necessary for that operative to apply to each item in the suite. An operative at a second or subsequent workstation can then also remove the items necessary for that operative to carry out their designated tasks. Accordingly, the storage container 39 can be used to convey the items necessary for the assembly of the items of furniture from the start of the production line to the appropriate workstation where the items are required by an operative.

In the present example, following mounting of the pallet 5 with a storage container 39 suspended therefrom on the first workstation 3 in a series of workstations 2, a skeleton or frame for an item of furniture is placed on the pallet 5 at the first workstation in the series 2. The pedal brake 36 is then actuated to lock the pallet 5 in position on the 0 * ? 2 workstation 3 to prevent movement of the pallet 5 on the rollers 34 and 35. The pallet 5 is oriented so that the bridging bars 53 and 54 are disposed towards the next workstation 3 in the series of workstations 2.

An operative can then remove the necessary items from the storage container 39, for example, the fabric arms of an armchair and apply them to the skeleton or frame. For example, the operative can apply the fabric using an air gun or the like attached to the air hoses 12 suspended from the support rail 11. The operative has easy access from all angles to the item to be assembled or worked upon on the pallet 5 from either side of the workstation 3 and from within the work areas 4 between the workstations 3 in the series 2. Accordingly, the operative is not restricted in any way in movement or accessibility to the item to be assembled so that the operative can easily and quickly perform the necessary task.

Following completion of the task by the operative at the workstation 3 the pedal break 36 is released and the pallet 5 can be slid or rolled on the rollers 34 and 35 to the next workstation 3 in the series 2. The bridging bars 53 and 54 roll onto the support rollers 35 of the next workstation 3 in the series 2 to bridge the gap defined by the work area 4 between each workstation 3. The pallet bearing the item of furniture is therefore rolled or slid into position on the following workstation 3 and the pedal brake 36 then actuated as previously described to lock the pallet in position.

The operative at the next workstation 3 can then carry out the tasks allotted to the operative for that workstation 3. Meanwhile, a pallet 5 can be loaded onto the first workstation 3 so that the operative at the first workstation 3 carries out his allotted task, for example, application of fabric to arms of a second piece of a three piece suite of furniture.

The above mentioned process is repeated such that pallets 5 are moved along the production line 1 from workstation 3 to workstation 3 so that the operative ultimately can work simultaneously without interruption resulting in a continuous manufacturing process on the product line 1.

Following completion of an item of furniture on a pallet 5, the item of furniture is removed from the pallet 5 at the end of the production line 1. The pallet 5 is removed from the workstation 3 and mounted on the return track 6 as previously described. The pallet can then be urged along the inclined return r track 6 to the beginning of the production line 1 to be reused.

An important advantage of the invention is that the items being produced on the production line 1 in accordance with the invention can remain on a pallet 5 which is transferred from workstation to workstation along the production line 1 without requiring manual lifting or conveying of the item of furniture from workstation to workstation and thereby resulting in enhanced safety. In addition, heretofore, it has been necessary to await assistance from a colleague before an operative could lift a heavy item of furniture from workstation to workstation thereby resulting in loss of efficiency. Alternatively, operatives may attempt to lift heavy items single-handedly resulting in safety risks .

In addition, the invention provides a production line facilitating continuous movement or processing of items mounted on pallets which are moveable from workstation to workstation but yet allow access to the item from all angles around the workstation due to the presence of the work area 4 between each workstation 3.

Claims (33)

1. An assembly system comprising at least two workstations, a workspace between each workstation, a pallet mountable on and moveable between each 5 workstation across the workspace and conveying means on each workstation for supporting the pallet on and conveying the pallet between the workstations such that the pallet can be temporarily supported between the workstations across the workspace. 10 2. An assembly system as claimed in Claim 1 characterised in that the assembly system further comprises a return track for returning the pallet to a first workstation following conveyance of the pallet between workstations. 15 3. An assembly system as claimed in Claim 1 or Claim

2. Characterised in that the workstation comprises a brake for locking the pallet in position on the workstation.

3. 4. An assembly system as claimed in any of Claims 1 20 to 3 characterised in that the conveying means comprises at least one sliding track for sliding the pallet across and between the workstations.

4. 5 . An assembly system as claimed in Claim 4 '5' J characterised in that the track comprises rollers.

5. 6. An assembly system as claimed in any of Claims 1 to 5 characterised in that the pallet is adapted to carry a storage container. 5

6. 7. An assembly system as claimed in any of Claims 1 to 6 characterised in that the workstation comprises four upstanding legs having a sliding track mounted between each pair of legs.

7. 8. An assembly system as claimed in any of Claims 4 10 to 7 characterised in that the sliding track is provided with carrying rollers for conveying the pallet.

8. 9. An assembly system as claimed in Claim 8 characterised in that the sliding track is provided 15 with two support rollers either side of the carrying rollers for supporting the pallet across the workspace.

9. 10. An assembly system as claimed in any of Claims 3 to 9 characterised in that the brake comprises a pedal actuated brake. 20

10. 11. An assembly system as claimed in Claim 10 characterised in that the pedal actuated brake comprises a pallet engaging means, the pallet engaging means being pivotally connected by a link arm to the brake pedal such that displacement of the pedal urges the pallet engaging means into engagement with the 5 pallet.

11. 12. An assembly system as claimed in claim 11 characterised in that the pallet engaging means comprises a brake pad to urge the pallet against a sliding track. 10

12. 13. An assembly system as claimed in any of the preceding claims characterised in that the pallet comprises a frame having a top board mounted thereon.

13. 14. An assembly system as claimed in any of Claims 2 to 13 characterised in that the return track comprises

14. 15 an upper track disposed above and in parallel with a lower track to support a pallet in a substantially vertical disposition. 15. An assembly system as claimed in Claim 14 characterised in that the upper track and the lower 20 track comprise rollers for carrying the pallet.

15. 16. An assembly system as claimed in Claim 15 characterised in that the axis of rotation of the lower 9/0^72 rollers is perpendicular to the axis of rotation of the upper rollers, the axis of rotation of the upper rollers being along a horizontal axis and the axis of rotation of the lower rollers being along a vertical 5 axis such that the pallet is mountable on the upper rollers and slidable against the lower rollers.

16. 17. An assembly system as claimed in Claim 16 characterised in that the upper and lower tracks of the return track are inclined in parallel longitudinally 10 downwards from the last workstation to the first workstation.

17. 18. An assembly system as claimed in Claim 17 characterised in that the return track comprises stop means to hold the pallets on the return track. 15

18. 19. An assembly system as claimed in Claim 18 characterised in that the stop means comprises a gate biased against the upper track of the return track.

19. 20. A process for the manufacture of an article along a production line comprising 20 - at least two workstations having a workspace therebetween, mounting a pallet on a first workstation, carrying out a first operating step on an item on the pallet, conveying the pallet with the article from the first workstation to a second workstation across the workspace, 5 - the pallet being supportable by the workstations between the first and second workstations, effecting a second operating step at the second workstation, and the pallet and the article being accessible from 10 between the workstations, during each operating step.

20. 21. A process as claimed in Claim 20 characterised in that the operating steps comprise assembly steps.

21. 22. A process as claimed in Claim 21 characterised in 15 that the pallet is locked into position on the workstation during assembly.

22. 23. A process as claimed in Claim 22 characterised in that the pallet is conveyed on rollers mounted on the workstations . 20

23. 24. A process as claimed in Claim 23 characterised in that the rollers support the pallet across the workspace. 9 7 0-^72

24. 25. A process as claimed in Claim 24 characterised in that the assembled article is removed from the pallet following assembly.

25. 26. A process as claimed in Claim 25 characterised in 5 that the pallet is removed from the final workstation following assembly.

26. 27. A process as claimed in Claim 26 characterised in that the pallet is returned to the first workstation following assembly along a return track. 10

27. 28. A process as claimed in Claim 27 characterised in that the pallet is slid along the return track.

28. 29. A process as claimed in Claim 28 characterised in that the return track is inclined towards the first workstation. 15

29. 30. A process as claimed in Claim 29 characterised in that the article to be manufactured is an article of furniture .

30. 31. An assembly system substantially as hereinbefore described with reference to and as shown in the 20 accompanying drawings. '? 7 Ο ? 2

31. 32. A process for the manufacture of an article substantially as hereinbefore described with reference to and as shown in the accompanying drawings.

32.

33. An article of furniture whenever manufactured by a 5 process as claimed in any of Claims 20 to 30 or Claim 32 .