Panel loading method and panel-loading support device

A panel loading method for loading an inner panel to an outer panel that has a bent portion provided by bending a periphery thereof, the outer panel and the inner panel being overlapped to integrate the outer panel and the inner panel at the periphery thereof. The method includes: providing at least one of the outer panel and the inner panel by an elastic body; disposing the outer panel onto a panel receiver so that the bent portion is directed upward; placing a guide plate on or above the bent portion; loading the inner panel into the outer panel from above the guide plate; and inserting the inner panel into an inside of the bent portion.

CROSS-REFERENCE TO RELATED APPLICATION

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2010-015048 filed on Jan. 27, 2010, of which the contents are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a panel loading method for loading an inner panel to an outer panel and a panel-loading support device.

2. Description of the Related Art

A method for loading a workpiece to a hemming machine disclosed in Japanese Patent No. 3634149 employs a plurality of grippers821,822and823suspended from a robot hand81. The grippers821,822and823grip bent peripheries WOe of a plurality of circumferential sides of outer members WRO and WLO to load workpieces WR and WL onto the hemming machine. Specifically, each of the grippers821,822and823has a pair of gripper claws82band82c, one of the gripper claws82band82chaving a projection82dand the other of the gripper claws82band82chaving a recess82e. The bent peripheries WOe of the outer members WRO and WLO are gripped between the projection82dand the recess82eto be partially deformed. When the bent peripheries WOe of respective sides WOa, WOc and WOd of the outer members WRO and WLO are gripped by the grippers821,822and823, the (inner) gripper claw82balso serves as a workpiece retainer for preventing the uplift of the inner members WRI and WLI, thereby preventing misalignment of the inner members WRI and WLI relative to the outer members WRO and WLO in loading the workpiece onto the hemming machine. After loading the workpiece, the workpiece is hemmed.

Though the workpiece is loaded after the outer panel and the inner panel are overlapped, when a parting line of the panel comes to a side orthogonal to a loading direction as shown inFIG. 17, a bent portion (hemming flange)104that is bent at the periphery of the outer panel100interferes with an end of the inner panel102in the setting path of the inner panel102when the outer panel100and the inner panel102are overlapped.

In order to avoid such an interference, an end of the inner panel102are cut off as shown inFIG. 18or the outer panel100are pulled and stretched by a sucker106.

However, when an end of the inner panel102is cut off, an engagement length for hemming is reduced, so that fastening strength and, consequently, the accuracy and rigidity of the hemming are reduced. Specifically, since the outer panel100are folded back to hold the inner panel102to fasten the plate members during the hemming, when an end of the inner panel102is cut off, the fastening strength is lowered to cause a misalignment of the inner panel102and the outer panel100, resulting in decrease in the processing accuracy. When the outer panel100is pulled by a sucker, the outer panel100may not be sufficiently stretched depending on the shape and rigidity of the outer panel100. The technique disclosed in the above Japanese Patent No. 3634149 does not overcome the above deficiencies.

SUMMARY OF THE INVENTION

The present invention has been made in view of the above conventional problems. An object of the invention is to provide a panel loading method that allows an inner panel to be easily loaded to an outer panel having a bent portion provided by bending a periphery thereof, without lowering the hemming processing accuracy, and a panel-loading support device.

In order to attain the above object, a panel loading method according to an aspect of the invention is for loading an inner panel to an outer panel that has a bent portion provided by bending a periphery thereof, the outer panel and the inner panel being overlapped to integrate the outer panel and the inner panel at the peripheries thereof, the method including: providing at least one of the outer panel and the inner panel by an elastic body; placing the outer panel on a panel receiver so that the bent portion is directed upward; placing a guide plate on or above the bent portion; loading the inner panel to the outer panel from above the guide plate; and inserting the inner panel into an inside of the bent portion of the outer panel.

The method may further comprises: moving the outer panel and the inner panel upward; and, when the outer panel and the inner panel are moved upward, retreating the guide plate from a path of the outer panel and the inner panel in accordance with the upward movement of the outer panel and the inner panel.

In order to attain the above object, a panel-loading support device is used for loading an inner panel to an outer panel that has a bent portion provided by bending a periphery thereof, the outer panel and the inner panel being overlapped to integrate the outer panel and the inner panel at the peripheries thereof, the device including: a panel receiver on which the outer panel is placed so that the bent portion is directed upward and is located at a predetermined point; and a guide plate that is placed on or above the predetermined point.

In the above structure, the inner panel may be loaded to the outer panel by a downward movement of the inner panel from above the guide plate toward the outer panel placed on the panel receiver, the inner panel being inserted into an inside of the bent portion of the outer panel with an aid of the guide plate.

Further, the device may further include: a guide plate fixing portion that fixes an end of the guide plate so that the other end of the guide plate is placed on or above the predetermined point, in which the guide plate fixing portion comprises a rotary shaft and is rotated around the rotary shaft by a force applied on the guide plate in accordance with the upward movement of the outer panel and the inner panel.

According to the above aspect of the invention, by placing the outer panel on the panel receiver such that the bent portion is positioned on the upper side; placing the guide plate on the bent portion; and loading the inner panel onto the outer panel from above the guide plate, the inner panel can be easily loaded to the outer panel having a bent portion without impairing the accuracy and strength of the hemming.

Further, even when the bent angle of the bent portion of the outer panel is so acute that it is difficult to load the inner panel, the inner panel can be easily loaded. Furthermore, the inner panel can be loaded to the outer panel without damaging the outer panel and the inner panel.

When the overlapped outer panel and inner panel are moved upward from the panel-loading support device to be removed, the guide plate is retreated from the path of the outer panel and the inner panel. Accordingly, the outer panel and the inner panel can be easily removed.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A preferred embodiment of a panel-loading support device as well as a panel loading method implemented using the panel-loading support device according to the invention will be descried below in detail with reference to the attached drawings.

FIG. 1is a front elevational view showing an arrangement of a panel-loading support device10.FIG. 2shows a part of a cross section of the panel-loading support device10taken along II-II line inFIG. 1.FIG. 3shows another cross section of the panel-loading support device10taken along III-III line inFIG. 1. The panel-loading support device10includes: a panel receiver12on which an outer panel is placed; a first support14for supporting the panel receiver12; a guide plate16; a guide plate fixing portion18on which the guide plate16is fixed; a second support20for supporting the guide plate fixing portion18; and a base22as a base portion of the panel-loading support device10. Incidentally, in the following description, right and left, and up (upper) and down (lower) directions are respectively defined by right and left, and upper and lower directions of the panel-loading support device10in the front elevational view ofFIG. 1.

The first support14and the second support20are collinearly provided on the base22. The first support14is attached to the base22by a bolt (not shown). The second support20has a flange24, the flange24and the base22being attached by bolts26,26. The guide plate fixing portion18has a substantially T-shape in front view. The guide plate fixing portion18and a stay28that horizontally projects from the second support20vertically fixes a spring30.

The guide plate fixing portion18fixes a second end of the guide plate16provided by an elastic body so that a first end of the guide plate16is disposed at or above a predetermined point. The first end of the guide plate16that projects from the guide plate fixing portion18to the panel receiver12extends from an upper surface of the guide plate fixing portion18toward the predetermined point at a lower left side. The predetermined point refers to a position of a bent portion of an outer panel having the bent portion formed by bending a periphery thereof when the outer panel is placed on the panel receiver12so that the bent portion is directed upward. The outer panel is placed on the panel receiver12so that the bent portion is situated at the predetermined point and is directed upward.

The guide plate fixing portion18is pivotally supported by the second support20around a rotary shaft32. The second support20has a stopper42that blocks the rotation of the guide plate fixing portion18toward a side at which the panel receiver12is provided. The fixing portion18illustrated inFIG. 1is not applied with a force (neutral state). At this time, no force is applied against the spring30. When more than a predetermined level of a rightward force (i.e. a force in a direction away from the panel receiver12) is applied on the guide plate fixing portion18, the guide plate fixing portion18rotates rightward around the rotary shaft32. When the guide plate fixing portion18rotates rightward around the rotary shaft32, the spring30is stretched to generate a contraction force so as to restore the state of the guide plate fixing portion18to the state shown inFIG. 1.

The angle θ for the first end of the guide plate16to extend downward can be set as desired. As shown inFIG. 2, a recess36for accommodating an adjuster plate34for adjusting the height of the second end of the guide plate16is provided on the top side of the guide plate fixing portion18. Though two adjuster plates34are inserted into the recess36inFIG. 2, the number of the adjuster plate34may be altered as desired.

The second end of the guide plate16is fixed on the top surface of the guide plate fixing portion18by bolts38,38. As shown inFIG. 3, the guide plate16has elliptical holes40,40. The shafts of the bolts38,38are inserted into the holes40,40to fix the guide plate16on the top surface of the guide plate fixing portion18. The elliptical configuration of the holes40,40allows a fine adjustment of the guide plate16in A direction (i.e. a longitudinal direction of the guide plate16). Incidentally, each of the bolts38includes a shaft and a head.

Further, though the circle shown in a dashed line inFIG. 1represents a path of the first end of the guide plate16when the guide plate16is rotated by 360 degrees around the rotary shaft32, the guide plate fixing portion18does not actually rotate by 360 degrees.

Next, an operation of the panel-loading support device10will be described below. The outer panel52is placed on the panel receiver12by an industrial robot or a manual labor so that the bent portion50provided by bending a periphery of the outer panel52is directed upward. Specifically, the outer panel52is placed on the panel receiver12so that the bent portion50is located at the predetermined point and is directed upward.

FIGS. 4 to 6illustrate operations of the panel-loading support device10when the outer panel52is placed on the panel receiver12by the industrial robot or the manual labor. The outer panel52touches the guide plate16before being placed on the panel receiver12(seeFIG. 4). When the outer panel52is further descended, the guide plate16is pressed by the outer panel52to be curved (seeFIG. 5). Subsequently, the outer panel52is placed on the panel receiver12(seeFIG. 6). When the outer panel52is placed on the panel receiver12, the guide plate16recovers its neutral state by the reaction force caused by the curving. At this time, the guide plate16is placed on or over the bent portion50.

Then, the inner panel54is loaded onto the outer panel52from above the guide plate16by the industrial robot or manual labor to overlap the periphery of the outer panel52and an end of the inner panel54. Specifically, the inner panel54is descended from above the guide plate16toward the outer panel52placed on the panel receiver12in order to load the inner panel54onto the outer panel52. Then, with the aid of the guide plate16, the inner panel54is inserted to the inside of the bent portion50to overlap the peripheries of the inner panel54and the outer panel52, thus completing the loading of the inner panel54to the outer panel52. At least one of the outer panel52and the inner panel54is provided by an elastic body. In this exemplary embodiment, the outer panel52is provided by an elastic body.

FIGS. 7 to 10show the operation of the panel-loading support device10when the inner panel54is loaded onto the outer panel52to overlap the peripheries of the inner panel54and the outer panel52by the industrial robot or manual labor. Initially, when the inner panel54is descended toward the outer panel52from above the guide plate16(seeFIG. 7), the inner panel54is in contact with the guide plate16(seeFIG. 8). When the inner panel54is further descended, the guide plate16is curved to downwardly press the bent portion50of the outer panel52(an elastic body), thereby outwardly displacing the bent portion50. Thus, an end of the inner panel54(i.e. an end that touches the bent portion50) is smoothly inserted to the inside of the bent portion50(i.e. inside of the outer panel52) (seeFIG. 9). The panel receiver12disposed more remote from the bent portion50is more likely to cause an elastic deformation of the outer panel52. Conversely, the panel receiver12disposed closer to the bent portion50is more likely to result in a plastic deformation of the inner panel54. Accordingly, the panel receiver12is the more advantageously disposed away from the bent portion50.

When the inner panel54is descended by an industrial robot or by a manual labor, the inner panel54is introduced to the inside of the bent portion50of the outer panel52by the guide plate16. Then, the guide plate16restores its original shape by a reaction force caused by the curving, so that a periphery of the outer panel52is overlapped with the end of the inner panel54(seeFIG. 10). Here, when the guide plate16is removed from between the outer panel52and the inner panel54, the guide plate16recovers its original shape by the resilience thereof. At this time, the guide plate16is placed on or over the bent portion50.

As shown inFIGS. 7 to 10, in loading the inner panel54to the outer panel52, since the inner panel54can be introduced to the inside of the bent portion50of the outer panel52with the aid of the guide plate16, the inner panel54can be easily loaded to the outer panel52without impairing the accuracy and rigidity of the hemming.

Then, the outer panel52and the inner panel54are moved upward (i.e. lifted) to remove the panels from the panel-loading support device10by the industrial robot or manual labor.FIGS. 11 to 13show operations of the panel-loading support device10when the outer panel52and the inner panel54are ascended by the industrial robot or manual labor.

When the outer panel52and the inner panel54are ascended, the bent portion50touches the guide plate16to lift the guide plate16upward. Thus, a force is applied on the guide plate fixing portion18via the guide plate16, so that the guide plate fixing portion18is turned rightward around the rotary shaft32(seeFIG. 11). At this time, the spring30is stretched. When the outer panel52and the inner panel54are further ascended, further force is applied on the guide plate fixing portion18via the guide plate16, which turns the guide plate fixing portion18to further rightward around the rotary shaft32to substantially retreat the guide plate16from the upward movement path of the outer panel52and the inner panel54. The guide plate16becomes out of contact with the outer panel52as the outer panel52and the inner panel54are further ascended. Then, the guide plate fixing portion18returns to its neutral state by the contraction force of the spring30(seeFIG. 13).

As described above, by placing the outer panel52on the panel receiver12so that the bent portion50is directed upward; placing the guide plate16on the bent portion50; and loading the inner panel54to the outer panel52from above the guide plate16, the inner panel54can be easily loaded to the outer panel52having the bent portion50without sacrificing the accuracy and rigidity of the hemming. Further, the inner panel54can be easily loaded even when the bent portion50of the outer panel52is acutely angled and loading of the inner panel54is difficult. Further, the inner panel54can be loaded to the outer panel52without damaging the outer pane52and the inner panel54.

In addition, when the overlapped outer panel52and the inner panel54are moved upward to be removed from the panel-loading support device10, since the guide plate16is retreated from the path of the outer panel52and the inner panel54, the outer panel52and the inner panel54can be easily removed.

Next, the relationship between the guide plate16and the bent portion50will be described below. When the length h for the guide plate16to be projected from the bent portion50(seeFIG. 14) is large, the guide plate16is held between the outer panel52and the inner panel54when the inner panel54is descended to the lowest position, so that the guide plate16cannot be returned to the neutral state (the state shown inFIG. 10). On the other hand, when the length h is short, the inner panel54cannot easily go into the inside of the outer panel52. Accordingly, after various experiments, it has been proved that the length h is preferably in a range from 2 to 3 mm. Further, experiments also proved that an approach angle α of the guide plate16to the bent portion50affects the accessibility of the inner panel54to the inside of the outer panel52. The approach angle of the guide plate16to the bent portion50is preferably in a range from 70 to 80 degrees (the closer to 80 degrees is the more preferable), according to the results of various experiments.

Further, when the rotary shaft32is located at a low position (e.g. at the position of the point B shown inFIG. 13), the rotation amount of the guide plate fixing portion18for retreat of the guide plate16is magnified. Accordingly, the rotary shaft32is advantageously disposed at the point A shown inFIG. 13. The position of the point A is an intersection of a horizontal line passing through the end (the first end) of the guide plate16and a vertical line passing through the center of the rotary shaft32. Thus, the guide plate16can be retreated with a less amount of rotation.

The above-described exemplary embodiment may be modified as described below.

(1) Though the rotated guide plate fixing portion18is returned by the spring30when the outer panel52and the inner panel54are removed from the panel-loading support device10, a cylinder may be used instead of the spring30.FIGS. 15 and 16show operations of a panel-loading support device using a cylinder in place of the spring30.FIG. 15shows the panel-loading support device60when the inner panel54is completely loaded to the outer panel52.FIG. 16shows the panel-loading support device60when the outer panel52and the inner panel54are moved upward to be removed from the panel-loading support device60.

The panel-loading support device60includes: the panel receiver12, the first support14; the base22; the guide plate16; the guide plate fixing portion62; the second support64; a cylinder66; and a box portion68. In the following description, the same or similar components as those shown inFIG. 1will be denoted by the same reference numerals, and only the components different from those shown inFIG. 1will be described. The box portion68is provided on the base22to support the second support64and the cylinder66. The box portion68has a drive controller (not shown) for controlling the movement of the cylinder66.

The second support64pivotally supports the guide plate fixing portion62so that the guide plate fixing portion62is capable of rotation around a rotary shaft70. The cylinder66pivotally supports a guide plate fixing portion62so that the guide plate fixing portion62is capable or rotation around a rotary shaft72. The rotary shaft72is slidable along the longitudinal direction of the guide plate fixing portion62. The guide plate fixing portion62rotates around the rotary shaft70. As shown inFIG. 2, the guide plate fixing portion62is provided with the recess36for adjusting the height of the second end of the guide plate16. The height of the second end of the guide plate16can be adjusted by inserting the adjuster plate34in the recess36. The guide plate16is fixed on the guide plate fixing portion62by the bolts38,38.

As shown inFIG. 15, until the outer panel52is completely loaded to the panel receiver12, the first end of the guide plate16is located on or above the predetermined point by the cylinder66. When the inner panel54is loaded and the outer panel52and the inner panel54are to be moved upward, as shown inFIG. 16, the above-described drive controller contracts the cylinder66to turn the guide plate fixing portion62rightward around the rotary shaft70, thereby retreating the guide plate16from the path of the outer panel52and the inner panel54. Incidentally, since the operation of the panel-loading support device60until the inner panel54is completely loaded to the outer panel52is the same as the above-described exemplary embodiment, the description is omitted.

(2) Though the guide plate16is retreated from the path of the outer panel52and the inner panel54by the rightward rotation of the guide plate fixing portion18around the rotary shaft32, the guide plate16may be retreated in another way. For instance, the second support20may be turned around a vertical axis thereof to horizontally move the guide plate fixing portion18to retreat the guide plate16.

The exemplary embodiment of the invention has been described above. However, it should be noted that the technical scope of the invention is not limited to the above exemplary embodiment. It is clear to those skilled in the art to make various modifications or improvements to the above-described exemplary embodiment. Any embodiment bearing such modifications or improvements can be included in the technical scope of the invention as mentioned in the claims below.