JP2005238353A - Assembling method for two-wheeled motor vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a highly productive assembling method for a two-wheeled motor vehicle by which a facility area is reduced and assembly work is efficiently executed. <P>SOLUTION: The assembling method for a two-wheeled motor vehicle is composed of processes for: loading components for one two-wheeled motor vehicle on a component truck 54 while moving the component truck 54 in a component stock area storing assembly components to be assembled to a vehicle body frame F; arranging the component truck 54 loaded with the assembly components for one two-wheeled motor vehicle around a truck 10 for assembly, a process for laying an engine E on the truck 10 for assembly, a process for mounting the vehicle frame F to the engine E laid on the truck 10 for assembly; and assembling the assembly components to the vehicle frame F. These processes are handled by one to four workers. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a motorcycle assembling method capable of efficiently performing assembling work in various kinds of small volume production.

Conventionally, in a motorcycle production line equipped with an overhead conveyor and a slat conveyor, automatic machines and workers are allocated to each work station on the production line, work is allocated, and as the car body moves on the line, the car body changes The line that assembles the parts is organized. This method is called a line production method (for example, see Patent Document 1).
JP-A-7-223575 (FIGS. 5 and 9)

Patent document 1 is demonstrated based on the following figure.
FIG. 14 is a front view of a conventional self-propelled assembly cart. The self-propelled assembly cart 200 includes a cart body 201 and casters 202... The same applies to the following.), A drive unit 203 disposed inside the casters 202, a battery 204 disposed in the vicinity of the drive unit 203, and the upper surface of the carriage body 201 support the front wheels Wf. It comprises a front lifting table 205 and a rear lifting table 206 that supports the rear wheel Wr.

FIG. 15 is a diagram showing a layout of a conventional assembly line. The assembly line is a main assembly line in which various parts are assembled by a sub-assembly line L1 for assembling a main part of the motorcycle V and a self-propelled assembly carriage 200. L2 and distribution zones Z1 and Z2 for supplying various parts to the main assembly line L2 are configured as main elements.
The operator runs the self-propelled assembly cart 200 on the main assembly line L2 and assembles the parts.

Such a line production system consists of a large number of assembly processes and is suitable for small-scale and large-scale production.
However, due to the diversification of market (customer) needs in recent years, a variety of products has been developed, and it is necessary to carry out a variety of small-quantity production, which is a production form in which many types of products are produced in small quantities at the production site. Has increased.

If a variety of small-volume production is required, a so-called cell production system in which one or a plurality of workers normally performs work on a stationary vehicle body becomes appropriate.
However, the cell production method is said to be poor in productivity, and it is preferable to have a high-productivity multi-product small-quantity production method that can be performed by a small number of workers.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a method for assembling a motorcycle that can perform assembly work efficiently and has high productivity.

  The invention according to claim 1 includes a step of loading a part truck on the parts cart while moving the parts cart in a parts stock area in which the parts to be assembled to the body frame are stored, and an assembly for one car. Arranging a parts cart loaded with parts around the assembly cart; mounting an engine on the assembly cart; attaching a body frame to the engine placed on the assembly cart; It comprises a process of assembling assembly parts to the body frame, and these processes are processed by 1 to 4 workers.

Since the assembly parts for one unit are prepared without excess or deficiency, there is no assembly failure of the parts.
In addition, since the work is finished when the parts cart is empty, it is possible to prevent parts from being attached or the like.

In addition, since the assembly parts are arranged around the assembly carriage, the operator can remove the parts by simply reaching out and can be quickly assembled to the body frame.
Therefore, although it is in the cell production method, the production efficiency can be brought close to the line production method.
Furthermore, since the assembly of the motorcycle can be completed for each assembly facility unit, the facility area can be reduced. Corresponding to the increase or decrease of the production model and the number of production units, it becomes easy to expand or narrow the number of assembly facilities and the required assembly area accordingly.

According to the first aspect of the present invention, assembly parts for one unit are prepared without any excess or deficiency in the parts cart, so that there is no assembly failure of the parts.
Further, since the work is completed when the parts cart is empty, there is an advantage that parts can be prevented from being attached.
There are at most four workers. If there are four workers, two people can be placed on the left and right of the body frame. By considering the work procedure and work sharing, the crossing and contact between the workers can be eliminated. However, the work efficiency can be improved.

In addition, since the assembly parts are arranged around the assembly carriage, the operator can remove the parts by simply reaching out and can be quickly assembled to the body frame.
As a result, there is an advantage that the production efficiency can be brought close to the line production method.
Furthermore, since the assembly of the motorcycle can be completed for each assembly facility unit, there is an advantage that the facility area can be reduced.

The best mode for carrying out the present invention will be described below with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.
FIG. 1 is a layout diagram of a factory to which the cell production method of the present invention is applied. A motorcycle assembly line 50 includes a parts stock area 51 for storing parts to be assembled, and a stamping area for stamping a production number on a frame. 52 and a cell area 53 for assembling work.

In the parts stock area 51, parts necessary for assembly are loaded on the parts cart 54 while moving the parts cart 54 in order to collect parts for assembly.
Thereafter, a parts cart 54 loaded with assembly parts for one motorcycle that has been loaded is disposed at a predetermined location around the assembly cart 10.

FIG. 2 is a perspective view for explaining a process of loading parts for one motorcycle on the parts cart, and shows a part of the parts stock area 51.
In short, the parts stock area 51 is a parts warehouse in which a plurality of parts shelves 55 and parts necessary for assembly work are stocked inside the parts shelves 55. This is an area provided with a movement path of the parts cart 54 provided in a predetermined width so that the parts cart 54 can move in the parts stock area 51.

The main components in the parts shelf 55 will be described. 58 represents a brake unit, 59 represents a collecting pipe, 61 represents a muffler, 62 represents a rear fork, 63 represents a front fork, Wr represents a rear wheel, and Wf represents a front wheel.
That is, in this process, assembling parts for assembling to the body frame stored in the parts stock area 51 are gradually moved to the passage in the parts stock area 51 while moving the parts cart 54 for one motorcycle. It can be said that it is a process of loading parts on the parts cart 54.

  Since the parts cart 54 has wheels 54 w, the operator pushes or pulls the parts cart 54 to move in the parts stock area 51, temporarily stops the parts cart 54 near the parts shelf 55, and assembles from the parts shelf 55. The necessary parts can be easily taken and the necessary number of parts are loaded on the parts cart 54.

  The worker 66R on the right side of the drawing places the brake unit 58 on the component cart 54 in the foreground and pulls the component cart 54 in the direction of the arrow D1. Further, the worker 66L on the left side of the drawing shows a state in which the parts cart 54 on which the loading of the assembled parts has been advanced is pulled in the direction of the arrow D2 and is transferred from the parts stock area 51 toward the cell area 53.

FIG. 3 is a perspective view for explaining a parts cart loaded with parts for one motorcycle, and shows an appearance of a parts cart 54 loaded with assembled parts in the parts stock area 51 (see FIG. 1) and other areas. .
The parts cart 54 has a cowl C, a rear wheel Wr, a front wheel Wf, a rear fork 62, a front fork 63, and a housing fixed on the cart 54 from the left to the right, from the bottom to the top. A small shelf 67 is placed. Then, the muffler 61 and other small parts are placed on the storage shelves 67.

FIG. 4 is an arrow view for explaining a process of arranging a parts cart loaded with assembly parts for one motorcycle of the present invention around the assembly cart.
The motorcycle assembling facility 70 is for assembling a motorcycle including a front carriage 11, a central carriage 14, and a rear carriage 12 in the approximate center of the equipment 70, that is, in order from the front to the rear of the assembling equipment 70. Standard parts such as bolts and nuts provided in front of the tool carts 71L and 71R, and left and right tool carts 71L and 71R provided with tools necessary for assembly so as to surround the cart 10 for assembling the motorcycle 10 The left and right standard parts carts 72L and 72R, the information standard cart 74 having an information terminal 73 for instructing the assembly information such as the assembly order of parts to the operator in front of the left standard parts cart 72L, The equipment is equipped with a parts cart 54 loaded with parts for one motorcycle adjacent to the information indicating carriage 74.

That is, the assembly facility 70 is a process in which a work floor is provided around the motorcycle assembly carriage 10, and the parts cart 54 loaded with the assembly parts from the parts stock area is moved and arranged on the outer periphery of the work floor. is there.
In FIG. 4, the tool carts 71L and 71R are arranged on the left and right sides of the assembly cart 10. However, the tool cart may be disposed only on one of the left side and the right side in consideration of workers and others.

  Further, although the parts cart 54 is disposed in front of the assembly cart 10, it may be disposed on either the left side or the right side, and there is no restriction on the position of the component cart 54.

76 is a small liquid injection facility for supplying oil, cooling water, fats and oils, fuel and the like.
The parts cart 54 is provided with wheels 54w so as to be movable. Similar to the parts carriage 54, the tool carriages 71L and 71R and the standard parts carriages 72L and 72R are also characterized in that they can be moved by being placed on the carriage 78.

  Since the parts cart 54 is movable, as described above, parts are loaded on the parts cart 54 in a separate area away from the motorcycle assembly facility 70, and parts for one motorcycle are prepared in the parts cart 54. Then, it can be moved to the cell area 53 (see FIG. 1).

  Conventionally, in the production of motorcycles, assembled parts are mostly supplied in lot units to the line side of the production line, and storage containers with various sizes and packing forms are not necessarily assembled for each part. It was not arranged along. The reason why it is not possible to arrange according to the assembling procedure is that the necessary space on the line side becomes excessive or the walking distance for taking out parts becomes long.

Therefore, in the conventional production, the assembly parts are not necessarily arranged according to the assembly procedure, so that the operator stores the corresponding parts while searching for the location of the parts suitable for the assembly procedure. It was necessary to walk to the storage container.
For this reason, at the time of assembling parts, there are at least four losses: loss of walking, loss of searching for parts, loss of parts to be assembled, and loss of wrong parts to be assembled.

  On the other hand, according to the assembly equipment of the present invention, since the parts cart 54 can be moved freely, the parts are sequentially loaded on the carriage in another parts stock area away from the assembly equipment 70 of the motorcycle. It is possible to prepare the parts for the parts in the parts carriage 54 and move them to the assembly equipment 70 of the motorcycle.

  The parts for one motorcycle are loaded in advance on the parts cart 54 with the mounting position for each part determined, so when assembling the parts, the loss of walking, the part searching for the part, which part should be installed? At least four losses related to assembly of parts, such as lost loss and loss of parts to be assembled, can be greatly reduced.

In addition to the arrangement of the placement positions of the parts in the parts cart 54, the operator can perform the assembly work more accurately by the information terminal 73 that displays the assembly order of the parts arranged in front of the assembly equipment 70. It becomes.
Since there is no excess or deficiency in the parts cart 54, the assembly parts for one car are prepared.
In addition, since the work is completed when the parts cart 54 becomes empty, it is possible to prevent parts from being attached or the like.

FIG. 5 is a perspective view for explaining a process of placing the engine on the assembly carriage, and shows that the engine E is placed on the central carriage 14 of the assembly carriage 10 using the lift device 81.
The lift device 81 includes a base 82, leg members 83, 83 provided on the lower surface 82 a of the base 82, four wheels 84 provided at the lower part of the leg members 83, 83, and a vertical direction from the base 82. A column member 85 standing upright, an arm member 86 extending horizontally from the column member 85, and lift means 87 attached to the tip of the arm member 86. Reference numeral 88 denotes a small cart.

  Using the lift device 81, the engine E is lifted from the small cart 88, and the engine E is placed on the engine support plate 41 of the central cart 26.

FIG. 6 is a diagram for explaining that the frame is placed on the assembly cart loaded with the engine of the central cart.
In (a), the engine E is placed on the engine support plate 41 of the central carriage 14.
In (b), the vehicle body frame F is mounted on the engine E loaded on the engine support plate 41. When the vehicle body frame F is attached to the engine E, there is nothing that blocks the periphery of the engine E, so that the assembly workability is extremely good, and the work burden on the operator can be kept low.

Hereinafter, the process of assembling the assembly parts to the vehicle body frame will be described with reference to FIGS.
FIG. 7 is a diagram for explaining that the rear wheel assembly part mounted on the rear carriage is attached to the frame placed on the central carriage, and the rear wheel assembly part 91 is placed on the rear wheel receiving plate 17 of the rear carriage 12 and By restricting the rear wheel Wr on the rear wheel receiving plate 17 by the wheel restricting means 35, the rear wheel subassembly portion 91 is fixed in an upright state.
Next, in order to unite the body frame F and the rear wheel assembly 91, the rear carriage 12 is brought close to the central carriage 14 on which the engine E and the body frame F are mounted.

FIG. 8 is a diagram for explaining that the front wheel subassembly part mounted on the front carriage is attached to the frame mounted on the central carriage. In order to unite the vehicle body frame F and the front wheel subassembly part 92, The front wheel subassembly 92 is brought close to the vehicle body frame F loaded on the central carriage 14.
The front wheel assembly 92 placed on the front carriage 11 is erected for easy understanding, but is actually placed on the front carriage 11 in a tilted state.

  FIG. 9 is a diagram for explaining that the front carriage is connected to the rear carriage. The front and rear carriages 11 and 12 are connected by the front and rear carriage connecting means 13, and the front wheel subassembly 92 and the vehicle body frame F of the motorcycle 90 are connected. The rear wheel subassembly portion 91 is in a combined state.

FIG. 10 is a view for explaining that the connecting rod on one side is removed and the central carriage is removed.
In (a), as preparation for removing the central carriage 14, the front wheel support 16 of the front carriage 11 and the rear wheel support 17 of the rear carriage 12 are raised by a predetermined amount, and the engine E and the engine support plate Make a gap with 41.
In (b), in order to remove the central carriage 14, one side of the front and rear carriage connecting means 13 arranged on the left and right is released, that is, one of the left and right connecting rods 29 is removed, and the central carriage 14 is removed from the motorcycle 90. Remove in the direction.

Since the front and rear carriage connecting means 13 is configured so that the front carriage 11 can be connected to and separated from the rear carriage 12, the central carriage 14 can be removed freely. In addition, since the front and rear carriages 11 and 12 are provided with lifters, the front wheel Wf and / or the rear wheel Wr of the motorcycle 90 can be raised for assembling the parts.
As a result, by removing the central carriage 14, the central carriage 14 does not become an obstacle to the assembly of lower parts such as mufflers and exterior parts such as cowlings.

  FIG. 11 is a diagram for explaining the lifting of the front lifter of the front carriage and assembling the parts. By lifting the front wheel receiving plate 16 of the front carriage 11, lower parts such as mufflers and cowlings, exterior parts, etc. Assembly can be performed easily.

  Among the assembly carts 10, at least the front cart 11 and the rear cart 12 each have a structure that can be raised and lowered. Assembly work can be performed with a small work posture.

FIG. 12 is a diagram for explaining that the assembly of the motorcycle is almost completed, and shows that the assembly of the motorcycle 90 is almost completed using the assembly facility 70 of the present invention.
When the assembly is completed, the front wheel Wf of the motorcycle is placed on the front carriage 11 and the rear wheel Wr is placed on the rear carriage 12. At this time, the vehicle body V can be held upright by the rear wheel restricting means 35 supporting the rear wheel Wr.

There are at most four workers, and if there are four workers, two workers can be arranged on the left and right sides of the body frame F, so that the work efficiency can be improved.
In addition, since the assembly parts are arranged around the assembly cart 10, the operator can remove the parts by simply reaching out or walking about one time, and can be quickly assembled to the body frame F.
Therefore, although it is in the cell production method, the production efficiency can be brought close to the line production method.

Furthermore, since the assembly of the motorcycle can be completed for each assembly facility unit, the facility area can be reduced. Corresponding to the increase or decrease of the production model and the number of production units, it becomes easy to expand or narrow the number of assembly facilities and the required assembly area accordingly.
Since the parts for one car are put together and loaded on the car, the assembly space around the car body can be made compact.

  In this embodiment, the tool trolleys 71L and 71R and the standard parts trolleys 72L and 72R are provided on the left and right assuming two-person work. However, in the case of one person work, the tool trolleys 71L and 71R and the standard parts trolley 72L are provided. , 72R may be arranged on only one side.

  On the contrary, even if it is a one-person operation, the tool carriages 71L and 71R and the standard parts carriages 72L and 72R may be provided on the left and right sides. If the tool carts 71L and 71R and the standard parts carts 72L and 72R are provided on the left and right sides, the operator does not need to carry tools or standard parts on the opposite side when assembling the components on the opposite side.

  Since the front carriage 11 and the rear carriage 12 are connected by the front and rear carriage connecting means 13, the front carriage 11 and the rear carriage 12 can be moved together.

  That is, the parts cart 54L loaded with the parts assembled from the left side of the vehicle body V and the parts cart 54R loaded with the parts assembled from the right side of the vehicle body V so as to surround the assembly cart Therefore, the distance that an operator walks with parts can be reduced.

If there are two workers, the workers can be arranged on the left and right sides of the vehicle body frame F so that each worker can take out the parts and assemble them without contacting each other.
If there is one worker, the worker can walk to the left and right of the body frame F, take out the parts from the carriage near the assembly position, and assemble them without carrying them.
It can be said that the number of workers is preferably one or two.

In any case, the parts can be taken out and assembled from the parts cart on the side of the assembly position of the body frame F and near the assembly position.
Because of the assembly, the walking distance while holding the parts is reduced, so the burden on the operator can be reduced.

  FIG. 13 is a diagram for explaining that the motorcycle that has been assembled is dismounted from the motorcycle assembly truck, and the front end of the assembly truck 10 is brought close to the motorcycle 90 that has completed the assembly work. It can be easily lowered from the cart by opening the rear wheel restricting means 35 against 10F. On the contrary, it is also possible to get off after moving the assembly cart 10 on which the motorcycle 90 is mounted to a place where the getting-off stand 93 is located.

Therefore, by using the assembly cart, the assembly operation can be completed without using lifting equipment such as a hoist or an overhead conveyor.
It is assumed that the inclination angle θ of the dismounting table 93 is not restricted.

  The present invention is suitable for assembling a motorcycle.

It is a layout diagram of a factory to which the cell production method of the present invention is applied. It is a perspective view explaining the process of loading the parts for one motorcycle on a parts cart. FIG. 6 is a perspective view for explaining a parts cart loaded with parts for one motorcycle. It is an arrow view explaining the process of arrange | positioning the parts trolley which loaded | assembled the assembly | attachment parts for one motorcycle of this invention around the assembly trolley | bogie. It is a perspective view explaining the process of mounting an engine on the assembly cart. It is a figure explaining mounting an engine and a frame on the bogie for assembly of a central bogie. It is a figure explaining attaching the rear-wheel subassembly part mounted in the back part trolley to the flame | frame mounted in the center trolley | bogie. It is a figure explaining attaching the front wheel subassembly part mounted in the front trolley to the frame mounted in the central trolley. It is a figure explaining connecting a front truck to a rear truck. It is a figure explaining removing the connecting rod on one side and removing the central carriage. It is a figure explaining raising the front part lifter of a front trolley, and assembling parts. It is a figure explaining that the assembly of a motorcycle is almost completed. It is a figure explaining getting off the completed motorcycle from the dolly for motorcycle assembly. It is a front view of the self-propelled assembly cart of the prior art. It is a figure which shows the layout of the assembly line of a prior art.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... (Motorcycle) Assembly cart, 11 ... Front cart, 12 ... Rear cart, 14 ... Central cart, 51 ... Parts stock area, 54L, 54R ... Parts cart, 70 ... Motorcycle assembly equipment, 71L, 71R ... tool cart, 90 ... motorcycle, F ... body frame, E ... engine, V ... body.

Claims (1)

In the parts stock area where the parts to be assembled to the body frame are stored, the process of loading one part on the parts cart while moving the parts cart;
Arranging a parts cart loaded with the assembly parts for one vehicle around an assembly cart;
Placing the engine on the assembly carriage;
Attaching the body frame to the engine mounted on the assembly carriage;
It consists of the process of assembling the assembly parts to the body frame,
A method for assembling a motorcycle, wherein one to four workers process these steps.

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