System and method for an assembly line quick changeout fixture

A conveyor hanger assembly includes an upper fastening end configured to mechanically couple to a conveyor, a lower fastening end configured to couple to an assembly component carrier, and a locking assembly including a locking body extending in longitudinal alignment with and between the upper fastening end and the lower fastening end, and a locking collar positionable between a locked position and an unlocked positioned.

FIELD

The field of the disclosure relates generally to and more particularly to systems and methods for quick-changing component conveyor carriers during manufacturing.

BACKGROUND

At least some production or assembly lines employ conveyors to transport components, also referred to as conveyor carrier components, between different stations of the production line. Some known conveyors are mounted to an overhead rail, and roll along that rail to move components between stations on the production line. During vehicle manufacturing, it is necessary to periodically changeover from a first lineup of conveyor carrier components to a second lineup of conveyor carrier components. Such changeover may be necessary when the assembly line is switched from producing one type of component, such as a model of automobile to another model of automobile.

During a change-over, portions of the conveyor may need to be replaced or modified in order to transport the second lineup of conveyor carrier components. For example, a first component hanger designed to hold the first lineup of conveyor carrier components may need to be removed and replaced with a second component hanger designed to hold the second lineup of conveyor carrier components. Typically, the component hanger is bolted to the conveyor. To replace the first component hanger, the bolt is removed, the second component hanger is positioned with respect to the conveyor, and a bolt is again used to couple the second component hanger together with the conveyor. In addition, tightening of the bolt, or bolt and nut combination, may need to be verified with a torque wrench or other torque measuring device to comply with safety specifications.

Moreover, during the change-over, the production or assembly line is not producing the product it was intended to produce, therefore the production or assembly line is not producing revenue. Minimizing production or assembly line downtime is a much sought after goal. One way to minimize downtime is to make the change-over process simpler and less costly.

SUMMARY

In one aspect, a conveyor hanger assembly includes an upper fastening end configured to mechanically couple to a conveyor, a lower fastening end configured to couple to an assembly component carrier, and a locking assembly including a locking body extending in longitudinal alignment with and between the upper fastening end and the lower fastening end, and a locking collar positionable between a locked position and an unlocked positioned.

In another aspect, a method of quick changeout of a conveyor carrier includes receiving a first assembly component carrier to be removed from a conveyor, translating a locking collar of a conveyor hanger assembly longitudinally away from the first assembly component carrier thereby releasing a locking assembly. The method further includes pivoting the assembly component carrier approximately 90° with respect to the conveyor hanger assembly, and disengaging the assembly component carrier from a lower fastening end of the conveyor hanger assembly.

In yet another aspect, an assembly line includes a conveyor for moving an assembly from a first point to a second point along the assembly line and a conveyor hanger assembly. The conveyor hanger assembly includes an upper fastening end configured to mechanically couple to a conveyor, a lower fastening end configured to couple to an assembly component carrier, and a locking assembly. The locking assembly includes a locking body extending in longitudinal alignment with and between the upper fastening end and the lower fastening end. The locking assembly also includes a locking collar positionable between a locked position and an unlocked positioned.

DETAILED DESCRIPTION

The following detailed description illustrates embodiments of the disclosure by way of example and not by way of limitation. It is contemplated that the disclosure has general application to realigning a conveyor system for a quick changeover between a first assembly process and a second assembly process.

Embodiments of an assembly line conveyor quick change-over apparatus and method of affecting a quick change-over are described herein. When a conveyor assembly line system is shutdown to change-over to, for example, a new model of an assembly, time to complete the change-over is of the essence. Expenditure of labor resources is also tightly controlled. Consequently, to meet these competing goals, tool-less hardware and simpler change-over processes are needed. The presently disclosed conveyor hanger assembly is operable during a change-over to replace a first assembly component carrier with a second assembly component carrier without tools. The conveyor hanger assembly positively captures the assembly component carrier using a locking assembly having a multiple step locking feature.

The following description refers to the accompanying drawings, in which, in the absence of a contrary representation, the same numbers in different drawings represent similar elements.

FIG. 1is a perspective view of a conveyor hanger assembly100in a first locked position102.FIG. 2is a perspective view of conveyor hanger assembly100in a second unlocked or released position104. In the example embodiment, conveyor hanger assembly100includes an upper fastening end106configured to mechanically couple to a conveyor (not shown). In various embodiments, upper fastening end includes a longitudinally extending tab108having an aperture110therethrough. Tab108is configured to be received in a complementary slot in the conveyor (not shown). A lower fastening end112is configured to couple to an assembly component carrier (shown inFIG. 3). In various embodiments, lower fastening end112and the assembly component carrier (shown inFIG. 3) are coupled together in a pivot joint (shown inFIG. 4), in which lower fastening end112includes a pin114configured to receive an assembly component carrier hook (shown inFIG. 3). A locking assembly116includes a locking body118extending along a longitudinal axis120in substantial alignment with and between upper fastening end106and lower fastening end112. A locking collar122at least partially surrounds locking body118and is positionable between locked position102and unlocked position104by translating locking collar122longitudinally along locking body118. Locking collar122may be biased to locked position102, for example, by a spring124or other resilient material or other structure, such as magnets. Alternatively, or in combination, locking collar122may be biased to locked position102by the weight of locking collar122(i.e., gravity pulls locking collar122toward locked position102).

FIG. 3is a perspective view of an assembly component carrier300that may be used with conveyor hanger assembly100. In the example embodiment, assembly component carrier300includes a conveyor hanger engagement end302, which may be formed with an aperture304or an assembly component carrier hook306. When formed with aperture304, assembly component carrier300may be secured to lower fastening end112using a locking pin308, such as, for example, a lynch pin or hitch pin. When formed as a pivot joint305(shown inFIG. 6) with assembly component carrier hook306, assembly component carrier300may be secured to lower fastening end112using locking assembly116. Assembly component carrier300also includes a component hanger310and an elongate body312extending between component hanger310and conveyor hanger engagement end302. Assembly component carrier300is configured to engage pin114when assembly component carrier300is positioned at an angle314of approximately 90° with respect to lower fastening end112.

FIG. 4is a perspective view of assembly component carrier300in the process of being installed on conveyor hanger assembly100. In the example embodiment, a force is applied to locking collar122to overcome the bias of spring124permitting assembly component carrier300to be pivoted 90° with respect to conveyor hanger assembly100. Assembly component carrier hook306is then able to be disengaged from pin114and lowered from lower fastening end112for removal. To reinstall a second replacement assembly component carrier300, the process is reversed.

FIG. 5is a flowchart of an example method500for a quick change-over of a conveyor carrier, such as, an assembly component carrier on an assembly line conveyor. In the example embodiment, method500includes receiving502a first assembly component carrier to be removed from a conveyor, translating504a locking collar of a conveyor hanger assembly longitudinally away from the first assembly component carrier thereby releasing a locking assembly, pivoting506the assembly component carrier approximately 90° with respect to the conveyor hanger assembly, and disengaging508the assembly component carrier from a lower fastening end of the conveyor hanger assembly.

Optionally, method500may include receiving a second assembly component carrier to be installed on the conveyor, and engaging the assembly component carrier on the lower fastening end of the conveyor hanger assembly at an approximate 90° angle314with respect to the conveyor hanger assembly. In various embodiments, assembly component carrier hook306of the assembly component carrier is engaged to a pin of the lower fastening end. Method500further may include pivoting the assembly component carrier into longitudinal alignment with the conveyor hanger assembly, and translating the locking collar longitudinally toward the first assembly component carrier thereby engaging the locking assembly. In various embodiments, translating the locking collar includes permitting the bias member to translate the locking collar into a locked position on the conveyor hanger assembly.

FIG. 6is a side elevation view of an assembly line600and conveyor system602that may be used with conveyor hanger assembly100and assembly component carrier300. In the example embodiment, conveyor system602is configured to transport components, also referred to as conveyor carrier components, between different stations of the assembly line, such as, a Station I604and a Station II606. Some known conveyor hanger assemblies100are mounted to a horizontal rail608, and roll along rail608to move components between stations604,606on assembly line600. Conveyor hanger assembly100includes lower fastening end112that is configured to couple to assembly component carrier300. In various embodiments, lower fastening end112and the assembly component carrier300are coupled together in pivot joint305, in which lower fastening end112includes pin114.

The foregoing detailed description illustrates embodiments of the disclosure by way of example and not by way of limitation. It is contemplated that the disclosure has general application to quick-changing of conveyor hangers on an assembly line and in other commercial and industrial environments. It is further contemplated that the methods and systems described herein may be incorporated into existing assembly lines, in addition to being maintained as a separate stand-alone quick-changing securement capability.

The above-described embodiments of a method and system of quick-changing of conveyor hangers on an assembly line provides a cost-effective and reliable means for using a double locking conveyor hanger assembly More specifically, the methods and systems described herein facilitate reducing an amount of time it takes to change-out a conveyor hanger assembly of a first type for conveying a first type of component along an assembly line to a conveyor hanger assembly of a second type. Instead of unbolting and rebolting the conveyor hanger assemblies being changed-out, the conveyor hanger assembly uses a biased locking collar to secure a pivot connection that holds a component carrier to the conveyor hanger assembly. As a result, the methods and systems described herein facilitate quick-changing of conveyor hanger assemblies on an assembly line in a cost-effective and reliable manner.