Distortion training table

An apparatus and methods for training workers to recognize distortions. One example method includes positioning vacuum arms on a tilt-table top of a distortion training table situated in a horizontal position. The method further includes positioning locator arms on the tilt-table top in proximity to the vacuum arms, positioning a body panel on the locator arms to situate an inner surface of the body panel adjacent to each of the vacuum arms, applying suction to the inner surface of the body panel using the vacuum arms wherein the suction creates non-destructive distortions on an outer surface of the body panel, instructing the workers in tactile recognition of the distortions on the outer surface of the body panel, moving the tilt-table top from the horizontal position to a vertical position, and instructing the workers in visual recognition of the distortions on the outer surface of the body panel.

BACKGROUND

During the manufacture and assembly of vehicles, the outer surfaces of body panels can be damaged, causing distortions or flaws. These distortions and flaws can be magnified by the painting process, but are often difficult to detect on unpainted body panels. Failure to catch even the smallest defect can lead to scrapping the body panels after significant cost has been incurred in painting and assembly. Hence, many workers are trained to detect defects or distortions on the outer surfaces of body panels early in the assembly process.

A novel apparatus and methods of using the apparatus to train workers to recognize defects in vehicle body panels are described below.

SUMMARY

An apparatus and method for training workers to recognize distortions on vehicle body panels.

One aspect of the disclosed embodiments is a distortion training table apparatus. The apparatus includes a tilt-table top; a plurality of locator arms disposed on a top surface of the tilt-table top wherein a body panel can be positioned on at least some of the locator arms; and a plurality of vacuum arms disposed on the top surface of the tilt-table top in proximity to at least some of the locator arms wherein each of the vacuum arms can apply suction to an inner surface of the body panel to create non-destructive distortions on an outer surface of the body panel.

Another aspect of the disclosed embodiments is a method for training workers. The method includes positioning a plurality of vacuum arms on a distortion training table; positioning a plurality of locator arms on the distortion training table in proximity to at least some of the vacuum arms; positioning a body panel on at least some of the locator arms to situate an inner surface of the body panel adjacent to at least some of the vacuum arms; applying suction to the inner surface of the body panel using at least some of the vacuum arms wherein the suction creates non-destructive distortions on an outer surface of the body panel; and instructing the workers to recognize the distortions on the outer surface of the body panel.

Another aspect of the disclosed embodiments is a method for training workers. The method includes positioning a plurality of vacuum arms on a tilt-table top of a distortion training table wherein the tilt-table top is situated in a horizontal position; positioning a plurality of locator arms on the tilt-table top in proximity to at least some of the vacuum arms; positioning a body panel on at least some of the locator arms to situate an inner surface of the body panel adjacent to at least some of the vacuum arms; applying suction to the inner surface of the body panel using at least some of the vacuum arms wherein the suction creates non-destructive distortions on an outer surface of the body panel; instructing the workers in tactile recognition of the distortions on the outer surface of the body panel; moving the tilt-table top from the horizontal position to a vertical position; and instructing the workers in visual recognition of the distortions on the outer surface of the body panel.

DETAILED DESCRIPTION

A distortion training table and methods for training workers using the distortion training table are described here. The distortion training table includes a tilt-table top allowing a body panel of a vehicle to be displayed to workers and training personnel in both horizontal and vertical inspection positions. The distortion training table also includes a plurality of vacuum arms extending from the tilt-table top for providing varying levels of suction to an inner surface of the body panel. The suction can create non-destructive distortions, e.g. defects or deformations, of varying size and location on the outer surface of the body panel. Training personnel can instruct vehicle assembly workers through both visual and tactile recognition to detect a wide variety of distortion shapes and sizes in vehicle body panels without the need to scrap the body panels used during training.

FIG. 1is a perspective view of a distortion training table100with a table base101and a tilt-table top102in a mid-tilt position. The tilt-table top102can pivot between a horizontal position parallel to a top surface of the table base101and a vertical position perpendicular to the top surface of the table base101. In the example distortion training table100shown inFIG. 1, the pivot is located along one edge of the table base101and one edge of the tilt-table top102, though other pivot configurations are possible.

The distortion training table100includes a plurality of locator arms104disposed on the tilt-table top102. The locator arms104allow a body panel400,FIG. 4, to be positioned on the tilt-table top102when the tilt-table top102is in the horizontal position or the mid-tilt position. At least some of the locator arms104can include brackets106for engaging edges of the body panel400being positioned on the tilt-table top102. At least some of the locator arms104can also include means for changing position in relation to the body panel400.

One example means for changing the position of the locator arm104is a slide mount108which can move along a frame member or other portion of the tilt-table top102to position the locator arm104to properly hold different shaped body panels. As another example, a locator arm104can include a pivot mount (not shown) which can rotate the locator arm104in respect to the tilt-table top102to position the locator arm104. Example body panels400include sheet metal door panels, roof panels, hood panels, fender panels, and a variety of other panels having different shapes and sizes. Differences between body panels make adjustability of the locator arms104an important feature for the distortion training table100.

The distortion training table100also includes a plurality of vacuum arms110disposed on the tilt-table top102in proximity to at least some of the locator arms104. For example, the locator arms104can be attached to two parallel frame members making up two sides of the tilt-table top102and the vacuum arms110can be attached to two different parallel frame members making up the other two sides of the tilt-table top102as shown inFIG. 1. Other configurations of the tilt-table top102are also possible.

Each of the vacuum arms110can apply suction to an inner surface of a body panel to create non-destructive distortions on an outer surface of the body panel. In order to create non-destructive distortions, each of the vacuum arms110can include a suction cup112for engaging a body panel. At least some of the vacuum arms110can include means for connecting a source of pressurized air to the suction cups112. The size of the non-destructive distortions can vary based on the amount of suction applied to the body panel.

For example, the end of a vacuum line can be disposed in an opening in the suction cup112, and the vacuum line can extend through the body of the vacuum arm110to a fitting on the outside of the vacuum arm110for connection to a vacuum pump mechanism (not shown). The amount of suction applied can determine how large or small of distortion is created on the outer surface of the body panel400. Other methods of creating suction between the vacuum arms110and body panel400are also possible.

At least some of the vacuum arms110can also include means for changing position in relation to the body panel400. One example means for changing the position of a vacuum arm110is a pivot mount114which can rotate the vacuum arm110in respect to the tilt-table top102to position the vacuum arm110. As another example, the vacuum arm110can include a slide mount which can move the vacuum arm110along a frame member or other portion of the tilt-table top102.

The locator arms104can be positioned to receive a body panel400having a specific size and shape. The vacuum arms110can be positioned to create distortions at locations specified by training personnel. Once the body panel400is mounted to the distortion training table100and suction is applied using the vacuum arms110, workers can be instructed in tactile recognition of the distortions when the tilt-table top102is in the horizontal position. Then, the tilt-table top102can be pivoted to the vertical position, and workers can be instructed in visual recognition of the distortions.

FIG. 2is a top view of the distortion training table100ofFIG. 1with the tilt-table top102in a horizontal position. The brackets106are the only portion visible of the locator arms104since the locator arms104in this example extend perpendicularly from the tilt-table top102. The vacuum arms110are each positioned at various angles in respect to the tilt-table top102and the locator arms104. Each suction cup112and pivot mount114is also visible, and the suctions cups112are positioned to interface with an inner surface of a body panel400. The horizontal position of the tilt-table top102allows for ease of loading a body panel400onto the distortion training table100as well as for ease of changing the positions of the locator arms104and vacuum arms110as needed to accommodate body panels of various shapes and sizes.

FIG. 3is a side view of the distortion training table100ofFIG. 1with the tilt-table top102in a vertical position. The locator arms104extend perpendicularly from the tilt-table top102and are connected to the tilt-table top102using slide mounts108. The brackets106at the ends of the locator arms104are angled to assist in holding a body panel400between them. The vacuum arms110extend at various angles from the tilt-table top102and are connected to the tilt-table top102using pivot mounts114. The suction cups112at the ends of the vacuum arms110are positioned to interface with an interior surface of a body panel400. The vertical position of the tilt-table top102allows for ease of visual inspection of a body panel400, for example, a door panel, in a typical build position encountered during the vehicle assembly process.

FIG. 4is a perspective view of the distortion training table100ofFIG. 1with the tilt-table top102in a horizontal position and a body panel400fixed to the tilt-table top102. The body panel400shown inFIG. 4includes linear edges each having some curvature. The body panel400can be, for example, a door outer panel or a roof panel. Four brackets106are shown at the ends of four locator arms104holding the body panel400in position over four suction cups112shown in dotted-line shadow below the body panel400. The locator arms104are fixed to the tilt-table top102with slide mounts108. The position of the locator arms104can be adjusted both in mounting location along the tilt-table top102and in height or distance from the tilt-table top102.

FIG. 5is a side view of the distortion training table100ofFIG. 1with the tilt-table top102in a vertical position and a body panel400fixed to the tilt-table top102. A pressurized-air source500, for example, a vacuum pump, has been disposed below the distortion training table100. A plurality of vacuum lines502extend from the pressurized-air source500to the vacuum arms110. As described above, the vacuum lines502can also extend from fittings on the outside of the vacuum arms110through the bodies of the vacuum arms110up to the suction cups112.

When a vacuum is created at the suction cups112using the pressurized-air source500, the suction cups112engage the inner surface of the body panel400, allowing it to remain in a fixed position even when the tilt-table top102is in a vertical position. The amount of pressure or suction can be varied, for example, by the use of one or more air valves associated with the pressurized-air source500. A fairly low amount of suction can hold the body panel400in position against the brackets106and suction cups112. A higher amount of suction can create non-destructive distortions within the body panel400. The size and shape of the distortions can be varied with the amount of suction used. Further, the location of the distortions can be varied based on the positioning of the vacuum arms110.

One example method of using the distortion training table described inFIGS. 1-5above to train workers includes positioning a plurality of vacuum arms110on the distortion training table100and positioning a plurality of locator arms104on the distortion training table100in proximity to at least some of the vacuum arms110. The locator arms104and vacuum arms110can be positioned to accommodate a body panel400having a specific shape and size. At least some of the locator arms104can include a bracket106for engaging the body panel and at least some of the vacuum arms110can include a suction cup112for engaging the body panel by applying a source of pressurized air500to the suction cups112.

The method can also include positioning a body panel400on at least some of the locator arms104to situate an inner surface of the body panel400adjacent to at least some of the vacuum arms110. As described above, least some of the vacuum arms110and some of the locator arms104include means for changing position in relation to the body panel400. For example, both the locator arms104and vacuum arms110can be fixed to the tilt-table top102using slide mounts108or pivot mounts114. Once the body panel400is positioned on the locator arms104, the method can further include applying suction to the inner surface of the body panel400using at least some of the vacuum arms110having suction cups112. The suction can also be used to create non-destructive distortions on an outer surface of the body panel400. As described above, the size of the non-destructive distortions can vary based on the amount of suction applied to the body panel400.

The method can also include instructing the workers to recognize the distortions on the outer surface of the body panel400. Training personnel can instruct the workers in tactile recognition of the distortions when the tilt-table top102of the distortion training table100is in a horizontal position and in visual recognition of the distortions when the tilt-table top102of the distortion training table100is in a vertical position. After training personnel complete the step of instructing the workers to recognize the distortions, the method can include removing suction to disengage the vacuum arms110and to remove the non-destructive distortions from the outer surface of the body panel400.

Another example method of using the distortion training table100described inFIGS. 1-5above to train workers includes positioning a plurality of vacuum arms110on a tilt-table top102of a distortion training table100. The tilt-table top102is situated in a horizontal position. The method further includes positioning a plurality of locator arms104on the tilt-table top102in proximity to at least some of the vacuum arms110. The method further includes positioning a body panel400on at least some of the locator arms104to situate an inner surface of the body panel400adjacent to at least some of the vacuum arms110.

Once the body panel400is positioned, the method can further include applying suction to the inner surface of the body panel400using at least some of the vacuum arms110. The suction can create non-destructive distortions on an outer surface of the body panel400. The method can further include instructing the workers in tactile recognition of the distortions on the outer surface of the body panel400. Next, the method can include moving the tilt-table top102from the horizontal position to a vertical position and instructing the workers in visual recognition of the distortions on the outer surface of the body panel400. Each of the methods described above can be practiced on the distortion training table100shown inFIGS. 1-5.

The foregoing description relates to what are presently considered to be the most practical embodiments. It is to be understood, however, that the disclosure is not to be limited to these embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.