Abstract:
A fixture and method for aligning a vehicle fender and door, particularly a fixture for an assembly line point that attaches to a vehicle door and moves a front edge of the door to a spacing element, attaches to a vehicle fender, moves the fender to the spacing element and to a pre-defined 3-dimensional relationship with the door, and holds the fender in the pre-defined relationship while the fender is secured in place on the vehicle.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to methods and implements for aligning components on a vehicle during a vehicle manufacturing process. In another of its aspects, the invention relates to aligning a vehicle door and fender on a vehicle during manufacture. 
     BACKGROUND OF THE INVENTION 
     In the manufacture of automobiles on an assembly line, the automobile moves through a number of assembly points. Each of the assembly points, or stations, generally adds or adjusts components on the automobile. A mechanism at such an assembly point that manipulates components on and onto the automobile is generally known as a fixture. 
     Each fixture generally has a specialized task to perform. Various fixtures require varying levels of interaction with a human operator, from complete manual operation to complete automation. 
     One known fixture application is the alignment of front fenders on a body of the automobile relative to the front edge of each of the front automobile doors. This installation requires the proper orientation of the vehicle fender in each of three dimensions, relative to the respective door. The fender is generally formed with a rear edge to match the front edge of the door, so that a properly aligned fender and door will define a uniform gap therebetween. Proper vertical alignment aids in ensuring the uniformity of the gap. Proper horizontal alignment (front-to-rear of the automobile) results in an aesthetically pleasing seam that presents minimal discontinuity to the wind stream generated along the side of the automobile during forward movement of the vehicle at operating speed. Likewise, proper lateral alignment (into or away from the side of the car) will prevent the generation of unnecessary drag and wind noise during operation. 
     Apparatus and methods for aligning the fender and door are known, but require tedious and time-consuming manual adjustment by the fixture operator. The consumption of time and effort slows down the assembly line, increasing the cost of production. Furthermore such methods may still not result in the uniform product desired. 
     It would be advantageous to have a fixture and method whereby a door and fender can be aligned while on the assembly line, in a known and uniform, repeatable manner, with minimal input on the part of a human operator. 
     SUMMARY OF THE INVENTION 
     In one of its aspects, the invention includes a fixture for use on an automobile assembly line for removably attaching to an automobile fender and an adjacent door, and for aligning the fender to the door to create a uniform spacing therebetween. The fixture comprises: a door attachment portion for securing the fixture to the door, comprising at least one vacuum-actuated suction device; a fender attachment portion for securing the fixture to the fender, comprising at least one vacuum-actuated suction device; a spacing device for establishing a spacing between the door and the fender; and a transverse adjustment mechanism for moving the door attachment portion relative to the fender attachment portion. 
     In a further embodiment, the invention further comprises a lifting mechanism for positioning and holding the fender at a predefined height relative to the door. 
     In a further embodiment, the invention further comprises the transverse adjustment mechanism being adapted to move the door attachment portion relative to the fixture. 
     In a further embodiment, the invention further comprises a second transverse adjustment mechanism for moving the fender attachment mechanism relative to the fixture. 
     In a further embodiment, the invention further comprises a manual release for deactivating the vacuum-actuated suction devices of the door and fender attachment mechanisms. 
     In a further embodiment, the invention further comprises a probe for insertion into a corresponding aperture in the door, the probe being fixedly attached to the fixture. 
     In a further embodiment, the invention further comprises a switch for detecting a proximity of the fixture to one of the fender and door and activating a respective vacuum-actuated suction device. 
     In a further embodiment, the invention further comprises the spacing device comprising a blade for insertion between the door and fender. 
     In a further embodiment, the invention comprises a method of assembling a fender to a vehicle, comprising the steps of: aligning an assembly fixture with a door mounted on the vehicle; securing the fixture to the door; adjusting the position of the door relative to a known orientation on the fixture; aligning the fender at a known height relative to the fixture; securing the fixture to the fender; adjusting the position of the fender relative to a known orientation on the fixture; fixing the position of the fender relative to the door; and releasing the fixture from the door and fender. 
     In a further embodiment, the invention comprises a manually operated fixture within an automobile assembly line for removably attaching to an automobile fender and an adjoining door and aligning the fender to the door while maintaining a uniform gap or spacing therebetween. The fixture comprises: a door attachment mechanism for securing the fixture to the door, comprising a plurality of vacuum-actuated suction devices; a fender attachment mechanism for securing the fixture to the fender, comprising a plurality of vacuum-actuated suction devices; a probe for insertion into a corresponding aperture in the door, the probe being fixedly attached to the fixture; a spacing blade for defining a gap between the door and the fender, the blade being fixedly attached to the fixture; a lifting mechanism for positioning and holding the fender at a predefined height; a transverse adjustment mechanism for moving the door attachment mechanism relative to the fixture; a transverse adjustment mechanism for moving the fender attachment mechanism relative to the fixture; a switch for detecting a proximity of the fixture to one of the fender and door and activating a respective vacuum-actuated suction device; and a manual release for deactivating each of the vacuum-actuated suction devices of the door and fender attachment mechanisms. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
     FIG. 1 is a front view of a vehicle-engaging face of a fender and door alignment fixture according to the invention. 
     FIG. 2 is a front view of a control face of the fender and door alignment fixture of FIG.  1 . 
     FIG. 3 is a side view of a sample vehicle door and fender with the fender and door alignment fixture of FIGS. 1-2 shown in phantom in an engaged position. 
     FIG. 4 is a flow-chart depicting an operational sequence of the fender and door alignment fixture of FIGS.  1 - 3 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIGS. 1-2, a fender and door alignment fixture  100  according to the invention includes a door attachment portion  102 , a fender attachment portion  104 , a proximity actuation switch  106 , operator controls including disengagement paddles  210 , and an alignment portion comprising a spacing blade  140  and an aperture probe  130 . The door attachment portion  102  and the fender attachment portion  104  are movably mounted on the fixture  100 , while the spacing blade  140  and aperture probe  130  are fixedly mounted on the fixture  100 . 
     The door attachment portion  102  comprises a primary oval bellows suction cup  110  and a secondary suction cup  120 . The oval bellows suction cup  1   10  is attached to a sliding mechanism  112  so that the oval bellows suction cup  110  can slide relative to the fixture  100  and, particularly, relative to the spacing blade  140  and aperture probe  130 . The sliding action is in a transverse direction to the active side, or face of the suction cup  110 , and is in a direction towards or away from the spacing blade  140 . The sliding action is also in a plane parallel to the face plane of the fixture  100  directed toward the assembly line and vehicle. 
     The fender attachment portion  104  comprises a plurality of suction cups  180 ,  190 ,  192 . The fender attachment portion  104  is slidably mounted to fixture  100  so that it can also slide relative to the fixture  100  and, particularly, relative to the spacing blade  140  and aperture probe  130 . The sliding action is in a transverse direction to the active side, or face of the suction cups  180 ,  190 ,  192 , and is in a direction towards or away from the spacing blade  140 . The sliding action is also in a plane parallel to the face plane of the fixture  100  directed toward the assembly line and vehicle. 
     The suction cups  180 ,  190 ,  192  are further mounted to the fender attachment portion  104  on piston shaft mechanisms so that the suction cups  180 ,  190 ,  192  are moveable in a direction perpendicular to the fixture  100  and vehicle  10 , toward and away from the assembly line. 
     The spacing blade  140  has a thickness for determining the width of the gap between the fender and door, and is fixedly mounted to the fixture  100  at a prescribed position, both in height and attitude (angle) with respect to the horizontal. The spacing blade  140 , at the prescribed height and attitude, corresponds to a front edge of a vehicle door  20  as the vehicle  10  proceeds along the assembly line and comes to a stop in front of the fixture  100 . 
     In like fashion, the aperture probe  130  is fixedly mounted to the fixture  100  at a prescribed position. The aperture probe  130  is adapted, when properly aligned, to correspond to an aperture  22  on the vehicle door  20 , as shown in FIG.  3 . 
     The fixture  100  further comprises a second aperture probe  170  for determining the presence of an aperture  32  on fender  30  of vehicle  10 . The second aperture probe  170  is a switch/button that extends from the fixture  100 . This second aperture probe  170  is used to confirm that the vehicle  10  in front of the fixture  100  corresponds to a vehicle model selected by the operator of the fixture  100 . 
     The fixture  100  is adapted to function on multiple vehicle configurations or models; some vehicles will have an aperture  32  on fender  30  to align with the second probe  170  (e.g. a hole for a side marker light), and others will not. When a particular model of vehicle  10  comes before the fixture  100 , the operator of the fixture  100  will set a selector lever  220  on the fixture  100  for that particular model vehicle  10 . The fixture  100  is programmed to recognize, first, if the vehicle  10  is the type selected on the selector lever  220 , by the location or existence of, for instance, the aperture  32  for the side marker light on the fender  30 , which exists on some models and not on others. If the aperture  32  for the side marker light is absent when the selected vehicle  10  should have it, the fixture  100  will stop to allow correction by the operator. Once the fixture  100  confirms that the selected vehicle model is before it, it then commences a sequence specific to that vehicle model. An example of a sequence for a vehicle  10  follows and is depicted in the flow chart of FIG.  4 . 
     A vehicle  10  is moved into position on the assembly line opposite the fixture  100 . The fixture operator selects the vehicle type on selector  220  and grasps operator handgrips  200  to move fixture  100  toward vehicle  10 . The fixture operator directs fixture  100  so that aperture probe  130  aligns in door aperture  22  and spacing blade  140  aligns in front of the forward edge of door  20 . With probe  130  aligned with aperture  22  and spacing blade  140  generally aligned with the forward edge of door  20 , the operator moves fixture  100  toward door  20  until proximity switch  106  contacts door  20  and activates the oval suction bellows  110 . The oval suction bellows  110  attaches to door  20 . 
     The oval suction bellows is slidably mounted on fixture  100  and is moveable by a pneumatic piston arrangement. After attachment to door  20 , the bellows  110  is moved by the piston arrangement to draw the door  20  toward the spacing blade  140  until the front edge of the door  20  is positioned firmly and uniformly against spacing blade  140 . 
     The fender attachment portion  104  of the fixture  100 , meanwhile, is in position to begin engaging the fender  30 . Lift mechanism  108  is in position in the wheel well portion  40  of fender  30 . The model of vehicle  10  will determine which of blocks  150 ,  152  will engage wheel well portion  40 . Lift mechanism  108  includes pneumatic pistons  151 ,  153  adapted to raise blocks  150 ,  152 , respectively, against the wheel well portion  40 , thereby positioning the fender  30  at the correct height to align with door  20 . Suction cups  180 ,  190 ,  192  are movably mounted on the fixture on pistons so that they can extend from the fixture  100  until they contact the surface of fender  30 . A suction is activated within the suction cups  180 ,  190 ,  192  so that when the suction cups contact the surface of fender  30 , a vacuum is drawn to attach the suction cups  180 ,  190 ,  192  to the fender  30 . The fender  30  is then drawn toward fixture  100  until it contacts bumpers  160 ,  162 . Bumpers  160 ,  162  extend from fixture  100  a distance such that when fender  30  is drawn outwardly against bumpers  160 ,  162 , the face of fender  30  is in the proper planar relationship with the face of door  20  relative to a centerline of the vehicle  10 . The fender  30  is thus positioned slightly outwardly from the face of the door  20  so as to minimize the effects of drag and turbulence as the vehicle  10  travels down the road and air passes over fender  30  and door  20  and the seam or gap therebetween. 
     After the fender  30  is properly positioned vertically by lift mechanism  108  and outwardly against bumpers  160 ,  162 , a sliding block  154  is extended by a piston  155  against a rearward edge of wheel well portion  40  to push the fender  30  against the spacing blade  140 . With the fender  30  correctly oriented vertically and against spacing blade  140 , fender  30  and door  20  define a pre-defined, generally uniform gap therebetween. 
     The fixture  100  holds the fender  30  and door  20  in this aligned position while the fixture operator attaches the fender  30  to the vehicle body. With the fender  30  secured to the vehicle body, the fixture  100  can be released from the fender  30  and door  20 . 
     The fixture operator releases the fixture  100  from the fender  30  and door  20  by simultaneously activating the release paddles  210  while grasping the hand grips  200 . Activating the release paddles  210  releases the suction within all suction cups  110 ,  120 ,  180 ,  190  and  192 , and retracts the pistons on lift mechanisms  150 ,  152  and sliding block  154 . Release of these elements enables the operator to retract the fixture  100  from the vehicle  10  and the assembly line. By requiring simultaneous activation of the paddles  210 , the operator&#39;s hands are safely out of the mechanism of the fixture  100 . 
     The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.