Cockpit instrument panel carrier

A cockpit carrier includes a welded frame having a first clamp and a second clamp rotatably mounted therein defining an axis of rotation. The clamps adapted to receive a cockpit flame. A gearbox is mounted between the first clamp and a handwheel to allow for manual rotational manipulation of the cockpit frame. The cockpit carrier further includes a brake caliper mounted to the welded frame, the caliper having friction pads disposed therein and a spring mounted thereto to bias the caliper in an engaged position. A lever pivotally attached to the lame and the caliper allows for manual positioning of the caliper in a disengaged position. The gearbox further has an input shaft and a brake disc mounted thereto. The brake disc 12 is positioned within the friction pads such that the friction pads provide a braking force against the disc in the engaged position to secure the cockpit frame in a selected rotational position and such that the friction pads do not contact the disc in the disengaged positioning allowing for the manual rotational manipulation of the cockpit frame about the rotation axis.

TECHNICAL FIELD 
This invention relates generally to a workstation for supporting a large, 
heavy workpiece. In particular, this invention relates to a workstation 
which allows a worker to achieve an infinite number of positions from 
which to access a workpiece through the rotation of the workpiece about a 
single axis without external power assist devices 
BACKGROUND OF THE INVENTION 
It is well known in the manufacture of motor vehicles to utilize a 
workstand to support large, heavy pieces and permit assembly and testing 
of components thereof. Motor vehicles are typically assembled from modules 
and a typical workstand is constructed to allow worker access to permit 
successive steps of as much of the sub-assembly of a module as practical. 
Existing workstands are designed to allow the rotation of a workpiece to 
permit access from a number of angles. Many of these workstands utilized 
external drives, such as hydraulic or electric or air motors, to provide 
the rotation force necessary to manipulate cumbersome modules. In addition 
these workstands are typically anchored to the assembly floor to provide a 
stable base and to allow for safe access to an external power source. In 
addition, existing workstands generally utilize a shot pin locking 
mechanism which permits the positive rotational location of the workpiece 
in predetermined positions. Other existing rotary workstands utilize 
rotary locks. 
The modules for assembling motor vehicles have been growing larger and 
heavy and more complex in recent years. I here are manufacturing flow and 
cost advantages to performing as many operations as possible on a single 
module in a single rotary workstand. The increased size of these modules 
are making rotary manipulation using existing workstands difficult, 
expensive and inefficient. What is needed is a workstand that allows for 
the manual rotary manipulation of these modern modules for motor vehicles. 
The envisioned workstand would allow operators access to all aspects of a 
module during the manufacturing process with minimal effort and a minimal 
number of required operator movements. 
SUMMARY OF THE INVENTION 
This invention offers advantages and alternatives over the prior art by 
providing a workstation for manipulating a large, heavy workpiece which 
allows a worker access to the workpiece form any angle. The workstation 
preferably includes a gearbox and a large handwheel allowing for minimal 
manual effort to rotate the workpiece about a single rotational axis. The 
preferred workstation advantageously includes a braking system which 
allows for the positive positioning of the work piece at worker selected 
angular positions. 
These advantages are accomplished in a preferred form of the present 
invention by providing for a workstation which allows for the rotation of 
a workpiece about a single rotational axis and which is a self-contained 
unit requiring no external power assisting devices. The workstation 
includes a handwheel and gearbox reducing unit which allows for minimal 
manual effort to enable rotational positioning of the workpiece. In a 
preferred embodiment of the present invention a mechanically operated disc 
braking system provides an operator with an infinite amount of rotational 
adjustment about the rotational axis. The braking system includes a spring 
return fail safe lever to positively bias the braking system in an 
activated position. 
The above discussed and other features and advantages of the present 
invention will be appreciated and understood by those skilled in tile art 
from the following detailed description and drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring to FIG.1 there is shown a cockpit carrier, generally designated 
as 1, with cockpit frame 2 shown installed therein. Cockpit carrier 1 
includes a welded steel frame 3 having a pair of clamps 4, 5 to secure 
cockpit 2 within the carrier. Clamp 5 is attached to a hand drive 
assembly, generally referred to as 6, as best shown in FIGS. 2 and 3. More 
specifically clamp 5 is mounted to an output shaft 7 which is rotationally 
supported within a carrier bearing 8 and attached to gearbox 9 having an 
input shaft 31 (as best shown in FIG. 2) and finally attached to a 
handwheel 10. The gearbox 9 includes a rotation gear reduction between the 
input shaft 31 and the output shaft 7 and together with the diameter of 
the handwheel 10 provides an operator with sufficient mechanical advantage 
to rotate for example, a cockpit frame 2 (weighing 250 pounds when fully 
assembled) by exciting only a 10 pound force on the handwheel 10. Gearbox 
9 can be any commercial available gearbox that is capable of providing 
sufficient rotational gear reduction. 
In addition, the cockpit carrier 1 includes a braking system, generally 
referred to as 11, as best shown in FIG. 2. Braking system 11 includes a 
brake disc 12 attached to the gearbox input shaft 31 and positioned within 
a brake caliper 13. Brake caliper 13 is mounted to frame 3 and has 
friction pads positioned therein for selectively halting the rotation of 
the hand-drive assembly 6 and in turn the cockpit subassembly. The braking 
system 11 further includes lever 17 which allows for hand operation of the 
brake caliper 13. An operator moves lever 17 up (as shown in FIG. 2) which 
rotates pivot arm 16, translates link arm 15 and in turn rotates an 
actuation lever 14 which de-activates the brake caliper 13. Pivot arm 16 
and Braking system 11 further includes a spring 18 mounted between the 
frame 3 and pivot arm 16 to bias the pivot lever against stop 20 and 
thereby positioning actuation lever 14 and brake caliper 13 in an engaged 
position. In the engaged position the friction pads within the brake 
caliper 13 are forced against the brake disc 12 to prevent rotation of the 
drive assembly 6. The upward displacement of the lever 17 cause the force 
produced by spring 18 to be overcome and positioned in a disengaged 
position releasing the friction pads from contact with tile brake disc 12 
allowing rotation of the drive assembly 6. Stop 20 is an adjustable stop 
comprising a bolt 21 threaded through stop support bracket 22 and lock nut 
23 to allow for adjustment of the travel of pivot arm 16 and actuation 
lever 14 as the friction pairs wear during use. Similarly, stop 24 is 
comprised of bolt 25 threaded through stop support bracket 26 and locknut 
27 to provided an adjustable stop for the travel of pivot arm 16 in the 
disengage position. The brake disc 12 and brake caliper 13 brake system 11 
provides for infinite rotational adjustment of the drive assembly 6. Brake 
disc 12 is for example a 10 inch disc which is commercially available from 
a number of sources. Brake caliper 13 is also, for example available from 
a number of commercial sources. The braking system 11 together with the 
mechanical advantage of the gearbox 9 produce sufficient braking force to 
resist rotational movement of the cockpit frame 2 during manufacturing and 
handling operations. 
During the subsequent manufacturing operations cockpit 2, to produce a 
completed cockpit sub-assembly generally referred to as 19 as best shown 
in FIG. 4, an operator opens clamps 4, 5 as best shown in FIG. 1 and a 
cockpit frame 2 is loaded into the cockpit carrier 1 by a suitable load 
assist device (not shown). The operator closes clamps 4, 5 securing the 
cockpit frame 2 therein and the cockpit frame 2 within the cockpit carrier 
1 is transported to an assembly line (not shown) for build up operations. 
While the cockpit carrier 1 is transported and consequently utilized in 
assembly operations, spring 18 provides a fail-safe mechanism by 
sustaining sufficient force against pivot arm 16 and in turn actuation 
lever 14 to maintain the friction pads in contact with the brake disc 12 
to prevent rotation of the cockpit frame 2. As the cockpit carrier 1 is 
moved from station to station along the assembly line subsequent stations 
may require a unique rotary position of the cockpit frame 2 to facilitate 
access, view, and assembly of various components. At any particular 
station the operator lifts lever 17 which causes pivot arm 16 to move 
against stop 21 overcoming the biasing force produced by spring 18 thereby 
moving the actuation lever 14 placing the caliper 13 in a disengaged 
position. With the brake caliper 13 in the disengaged position the hand 
drive assembly 6 is free to rotate and the operator manually turns 
handwheel 10 to rotationally manipulate the cockpit frame 2. When the 
operator has positioned the cockpit fame in an optimal rotational position 
the lever 17 is released and spring 18 again biases the brake caliper 13 
into the engaged position and the cockpit frame 2 is prevented from 
rotation. After work is completed at a particular station along the 
assembly line the cockpit carrier 1 is indexed to a next station and the 
operator at the station repeats the rotational positioning process 
described herein above to select the optimal position for the station. 
As best shown in FIG. 4 cockpit carrier 1 is advantageously well suited 
used for diagnostic testing and quality control procedures on cockpit 
sub-assembly 19. The cockpit carrier 1 including the cockpit sub-assembly 
19 is positioned near a diagnostic tool 27 where test leads 28, 29, 30 are 
connected to various components within the cockpit sub-assembly 19. The 
cockpit carrier 1 of tile present invention permits the operator to 
manipulate the cockpit sub-assembly 19 into a number of rotational 
positions allowing access to connect the test leads and to perform various 
diagnostic tests all an optimal, albeit different, rotational position. 
Upon completion of the manufacturing operations, the cockpit sub-assembly 
19 is removed from the cockpit carrier 1 by opening clamps 4, 5 and 
removing the sub-assembly 19 utilizing a suitable load assist device (not 
shown). 
It will be understood that a person skilled in the art may make 
modifications to the preferred embodiments shown herein within the scope 
and intent of the claims. While the present invention has been described 
as carried out in a specific embodiment thereof, it is not intended to be 
limited thereby but is intended to cover the invention broadly within the 
scope and spirit of the claims.