Modular vehicle assembly system and method

A modular vehicle assembly system and methods for increased flexibility and adaptability of a high volume assembly facility which builds several vehicle models. In one example, the invention includes modular assembly equipment (AE) support pallets which are shipped to vendors for installation of selected AE equipment devices that are specific to a predetermined assembly operation and then validation tested prior to shipment. The modular AE pallets and AE devices are quickly installed and easily removable for maintenance or replacement. In other examples, modular AE support platforms and safety fencing are used to support ground level assembly operation and safer working environment.

TECHNICAL FIELD

The invention generally pertains to the field of product and vehicle assembly.

BACKGROUND

Traditional high volume manufacture and assembly of products, machines and vehicles has occurred in large assembly plants. These assembly plants have included multiple assembly lines where components are gathered, assembled and connected together. In the manufacture and assembly of vehicular bodies, the bodies typically include a skeleton of sheet metal components that are welded together through resistance spot welding, seam welding and brazing techniques to form what are commonly called “body-in-white” (BIW) structures.

With the growing need to efficiently build vehicles and accommodate varying consumer demand, assembly plants have strived to employ flexible build processes so that different vehicles and varying vehicle models including alternate vehicle bodies, can be built along the same assembly lines. The ability to quickly change over from building one type of body to another causes significant difficulty for facilities due to the limited amount of space around assembly lines and the time required to change over equipment and components that are specific to one vehicle body.

The design, build, installation and commission (testing or prove-out) of new assembly lines is an enormously time consuming and expensive endeavor for both suppliers and the customer vehicle original equipment manufacturers (OEM's) ultimately responsible for operation of the assembly facilities and production of the vehicles. Due to increased competition and consumer demand, there is continuous pressure from the OEM's for lower cost and higher efficiency assembly systems (higher vehicle or unit per hour throughput) and for those assembly systems to be 100 percent operational in a shorter amount of time.

Due to the multiple assembly systems, equipment and components that require sequenced operation to assemble a vehicle (or other product), the design of the overall assembly line traditionally required many stages. For example, the final design of equipment, for example called “Time B” equipment, that relies on a supporting structure, for example called “Time A” equipment, traditionally could not be completed until the design of its Time A supporting structure is complete. Once the various Time A support infrastructure and individual assembly systems were designed, built and installed, a substantial portion of the commission or testing of the Time B equipment traditionally could not occur until all of the Time A support structure and equipment is delivered and installed at the OEM assembly plant. This is further complicated by OEM's typically awarding portions of the assembly line Time A and Time B equipment to many different suppliers to leverage the respective supplier's expertise. If a supplier falls behind in the design, build or installation of Time A equipment, that can delay Time B equipment suppliers causing a cascading of delays through the remainder of the design, build, installation and commission stages. It would be further advantageous to have as many of the assembly equipment and systems be generic or non-model specific. That is, these systems and equipment may be used to build most or all variations of a product or vehicle which may have different models or features. These non-model specific systems and equipment (Time A) could then be fabricated, installed and commissioned even when final decisions about the product to be produced have not been made (which affect the Time B non-generic or model-specific assembly equipment and systems).

It has further been time consuming and costly for vehicle OEM's to change over an assembly plant or assembly lines to a new vehicle model or different vehicle altogether. Even simple to moderate changes to the assembly line equipment infrastructure can take days or weeks to complete leading to costly production downtime.

Prior assembly systems have employed specific assembly plant layouts to decrease the plant floor space required and increase efficiency in operations and vehicle throughput. For example, the ComauFlex system, produced by the same assignee of the present invention, has been widely employed by OEM's the details of which can be reviewed in U.S. Pat. No. 8,201,723 the entire contents of which is incorporated herein by reference and briefly discussed below. Details of variations of the ComauFlex assembly plant layout systems can further be found in U.S. Pat. Nos. 8,869,370; 8,713,780 and U.S. Patent Application Publication 2012/0304446 all assigned to assignee of the present invention and all incorporated herein by reference. These prior systems further reduced the need to store to-be-installed components and subassemblies next to the assembly line and specific assembly stations or cells which cluttered the assembly floor and complicated logistics.

Prior assembly systems have employed some modular vehicle assembly subsystems which provided advantages in new installations and accommodating batch and random vehicle builds where different vehicle models or types of vehicles could be built along the same assembly line with reduced changeover time. Prior assembly subsystems have employed modular robotic assembly stations or cells which could be placed end-to-end to accommodate a specified assembly line or series of operations. For example, each assembly station or cell included a modular, precision-manufactured to close tolerances scaffold frame structure and could be selectively equipped with the necessary number of industrial, multi-axis robots and end effectors for a specified assembly operation. Details can be found in the above-referenced U.S. Pat. Nos. 8,201,723; 8,869,370; 8,713,780 and U.S. Patent Application Publication 2012/0304446 all incorporated herein by reference.

Despite the numerous efficiencies and advantages prior assembly systems provide, many of the above-referenced complexities and disadvantages continue in the design, build, assembly and commission of these equipment and process subsystems, and the assembly system as a whole, in the field. For example, peripheral equipment used in vehicle assembly, for example liquid sealant dispensing devices and fastener feeders, required to support the robot assembly operations at a particular assembly station are traditionally placed on the plant floor and separate conveying systems required to transfer the sealant or fasteners to the robots positioned in the assembly cell for use. As another example, where floor-mounted robots are needed in an assembly cell, much time and effort is traditionally needed to precisely locate and mount the robots in positional relation to the other robots and equipment in the assembly cell. As another example, safety fencing used around an assembly line or cell cannot be designed and tested until most of the assembly cell equipment is designed and installed at the assembly facility.

BRIEF SUMMARY

Examples of the present invention include a modular vehicle assembly line having a plurality of assembly cells having modular systems and equipment which improves on the above complexities and disadvantages in prior assembly systems and methods.

In one example of the invention, a modular application equipment (AE) support pallet device is selectively used to elevationally support and secure application equipment, for example liquid sealant storage tanks and distribution pumps, above the assembly line and assembly tools, for example robots. The modular pallet is selectively connected to the assembly cell frame directly adjacent to, or in close proximity to, the robot (or other assembly tools or equipment) using the specific application equipment and further provides a simple logistical path to convey the consumable material, sealant, fasteners etc. directly into the assembly cell and the robot for application. In an example of a method of the invention, the modular pallet device can be pre-constructed and shipped to the application equipment supplier wherein the application equipment can be mounted and tested at the supplier prior to delivery and installation at the assembly plant. Power, data and material conveying cables and hoses for the mounted peripheral equipment can simply be connected to coordinating equipment at a system integrator's facility or directly at assembly plant for a “plug and play” device enabling efficient installation, connection and commission/testing at the assembly plant.

In another example of an aspect the invention, a modular assembly tool (AT) platform or tray is provided to easily locate and secure required assembly tools and associated AE devices to the modular assembly cell infrastructure. In one example, a floor-level modular robot platform is provided. In the example, an industrial programmable robot, control cabinet and associated accessory devices are preinstalled on a modular AT platform or frame which coordinates with the existing modular assembly cell infrastructure. The modular support platform similarly allows the equipment to be pretested prior to arrival at the system integrator or assembly plant and provides quick and precise positioning with the existing modular assembly cell infrastructure. The simple, secure and precise positioning of the robot relative to the platform, and the platform relative to the assembly cell or station, provides immediate, predictable and highly repeatable location of the robot to the other assembly cell equipment greatly reducing the time and effort to positionally orient, program, and calibrate the robot over traditional devices and methods. The exemplary modular AT platform further provides secure and predictable positioning of AE devices relative to the robot, for example weld tip dressers for spot welding gun end effectors connected to the robots, further adding to plug and play advantages on installation at the assembly plant as described above.

On the need for significant maintenance of the application equipment, or a model changeover at the assembly plant, the modular AE pallets and AT platforms having non-model specific or model-specific AE devices and assembly tools are simply “unplugged” from the non-model specific assembly structures and replaced with the new, refurbished and/or AE devices or assembly tool equipment for the new vehicle model that has been tested/commissioned prior to arrival at the assembly facility or line.

In another example of an aspect of the invention a modular guard fence is used with one or more aspects of the modular assembly station and modular inventive aspects noted above and discussed below. In an example, the guard fence includes a frame that is cantilevered from the assembly frame and, may, but in a preferred aspect, does not require connection to an assembly plant floor which was expensive and time consuming in conventional safety fences and guards. The exemplary fence includes an upper position and a lower position allowing selective access to assembly tools in the assembly station. In one example, a front panel is positioned between the assembly tools and control cabinets and AE devices of an AT platform. This prevents unauthorized access to the assembly tools while allowing access to the control cabinets and selected AE devices while the assembly tools are in operation.

In another example of an aspect of the invention a method of establishing and purchasing a vehicle (or other product) assembly line is presented. In the example, an assembly plant throughput is established and the number of individual assembly lines forming the complete assembly line is determined. The throughput for each assembly line is calculated to meet the overall throughput target. The required assembly line equipment and services are divided up into non-model specific infrastructure equipment and services that are non-vehicle model specific and vehicle model-specific systems.

The non-model specific systems may include the modular frames, conveyors and AE pallets and AT platforms. The non-model specific equipment is singly sourced to a supplier or a minimal number of suppliers. The vehicle model-specific assembly equipment is competitively bid, preferably on an individual assembly line by assembly line basis, the supplier awarded the individual line or lines being responsible for meeting the individual line throughput specification.

The method provides at least the advantages of simultaneous and parallel design activities for non-model specific and model specific equipment, immediate design release of the modular non-model specific technical details of the assembly lines, increased commission of the equipment at the suppliers and rapid installation and final commission at the assembly plant through connection of the modular assembly line components and application equipment mounted thereto. This results in compressed timing to design and install an assembly facility at lower cost and overall lowered business risk which is more evenly shared between the OEM and suppliers awarded portions of the business.

Other applications and aspects of the present invention will become apparent to those skilled in the art when the following description providing examples of the invention are read in conjunction with the accompanying drawings described below.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Examples of a modular vehicle assembly system and methods10are described below and illustrated inFIGS. 1-16. The exemplary assembly devices and systems are described as useful in high quantity assembling automotive passenger vehicles, but there are other applications for manufacturing and assembling other vehicles and products known by those skilled in the art.

Referring toFIG. 1, a known vehicle assembly line for producing sheet metal skeletons of passenger vehicles known as “body-in-whites” (BIW) is shown on an assembly plant floor14. In the example, a material entry area20, a material loading and sequencing or staging area30, and a plurality of assembly lines38(six shown inFIG. 1and identified as40-45as illustrated). Each assembly line38includes a vehicle-in-process travel path60running down each line40-45.

In the examples shown, two types of vehicle conveyors are particularly, but not exclusively, useful for transporting the partially completed vehicle body along path60and through assembly stations or cells56. As generally shown inFIG. 2, a pallet106generally supports a partially completed vehicle body (not shown). The pallet106is selectively moved along path60on a rail frame110having powered rollers to selectively move pallet106from assembly cell to assembly cell. An example of a powered pallet system is Comau LLC's VersaPallet brand system. Additional details can be found in U.S. Pat. Nos. 6,564,440 and 6,966,427 which are incorporated herein by reference.

As generally shown inFIGS. 3A and 3B, a useful overhead conveyor is Comau LLC's VersaRoll® brand conveyor including powered rollers along an upper frame rail which engage and move a downward extending carriage along path60through the assembly cells56. Additional details can be found in U.S. Pat. Nos. 6,799,673; 6,564,440 and 6,719,122 which are incorporated herein by reference. A useful system to monitor the position and stop the pallets106or overhead carriers90at desired positions in the assembly cells is Comau LLC's VersaCoder® system which uses a readable strip connected to the pallet/carriage and a reader. Further details can be found in U.S. Pat. No. 7,108,189 which is incorporated herein by reference.

In either a pallet-style106(FIG. 2) or overhead-style90(FIGS. 3Aand B) vehicle conveyor or carrier, one or more exemplary assembly lines40-45may include a lower assembly path60and an upper return path84as generally shown. In the examples shown, the assembly operations, for example spot welding of sheet metal subassemblies and components, occur along the lower level in assembly cells56by programmable industrial, multi-axis robots150described further below. The upper return path of travel84may be used to return empty pallets or carriers to be restocked with components or fitted with a partially completed vehicle body for additional assembly. Where an upper return path84and conveyor is used, a lift (not shown) positioned at the end of an individual assembly line may raise, for example and empty carriage or partially completed vehicle body, from the lower path of travel60to the upper path of travel84. Return of an empty transport carriage may occur if the partially assembled vehicle body is transferred to another carrier for continued assembly along downstream assembly lines.

In an alternate example not shown, depending on the vehicle or product to be built, the above referenced lift (not shown) may be positioned prior to the end of a line40-45to raise a partially completed vehicle to the upper path84. Further, an elevated transverse conveyor (not shown) may move a partially completed vehicle body from an upper path84of one line40-45to an adjacent line for further build or assembly processes.

As best seen inFIGS. 3Aand B, where an overhead conveyor90is used, a transverse tooling shuttle or conveyor device112may be used. The conveyor112allows for different tooling to accommodate different vehicle types to selectively move in and out of the assembly cell56along a path116that is substantially transverse to assembly path60. Further details of assembly plant layout, assembly lines, tooling shuttles, component carts and carriers useful with the present invention can be found in U.S. Pat. Nos. 8,201,723; 8,869,370, 8,713,780 and U.S. Patent Application Publication 2012/0304446 all of which are incorporated herein by reference.

Other plant layouts, assembly cells, conveyors and tooling devices and methods known by those skilled in the art may be used with the present invention.

Referring toFIGS. 3Aand B, an example of a modular vehicle assembly system10is illustrated. In the example, the system includes a pair of scaffold-like frames120. In the example, frame120includes a lower frame module124on each side of the assembly line path of travel60as generally shown (one assembly line described hereafter for convenience). In a preferred example, the lower frame module124is manufactured and assembled to close dimensional tolerances and rigidly and removable secured to the plant floor14through threaded studs connected to mounting plates secured to the floor14, typically concrete. In a preferred example, the lower frame modules124are precisely spaced laterally from a predetermined and known centerline of the assembly line60in the assembly facility. The longitudinal position of the lower frame124along the assembly line is also determined through known 3-dimensional coordinate reference positions in the assembly facility. These positions may be defined using a large template or jig using the assembly centerline.

Using the predetermined assembly line center line and proper longitudinal position of the lower frames, in one example, an assembly cell reference center point260for the assembly station is determined as best seen inFIG. 12. In a preferred example, the predetermined reference point260provides an accurate and known location in the X, Y and Z dimensional coordinates from which other modular assembly system equipment for example the frames120are located from to support precision assembly operations along the assembly line.

In a preferred example, the lower frames124include an entrance point, for example the leading frame portion upstream, and an exit point, for example the trailing or furthest portion of frame120downstream. The lower frames124are precisely positioned longitudinally along path60from the known center or reference point260to provide a structurally rigid and dimensionally precise foundation for locating upper frames130. The precision mounting location of the lower frames124along path60and precision mounting locations for the robots150connected to the frame120relative to the known reference point260of the assembly cell56provide accurate, precise and predictable orientation of the robots150for programming the movements of the robots150assigned functions in the assembly cell56. In a preferred example, the lower frames124are non-model specific. That is, lower frames124are standard or generic and do not depend on which type of vehicle or vehicle body (or other product) will be built. The exemplary lower frames124are designed to handle or accommodate the building of substantially all passenger vehicles. In an alternate example, the lower frames would be standard or non-model specific for other products that may have options or variations that can be ordered by customers.

As best seen inFIGS. 3A, B,5,67, an exemplary pair of upper frames130is illustrated. Each upper frame130is preferably precisely fabricated to small or close tolerances and mounted atop a respective lower frame124as generally shown (one described hereafter for convenience). Upper frame130includes vertical legs and an elevated floor136longitudinally extending along and parallel to path60forming a rigid scaffold-like assembly frame. Floor136is of a width140which is preferably about 60 inches. Other widths140and dimensions of upper frame124suitable for the application and known by those skilled in the art may be used. Precision-machined mounting surfaces (not shown) provide mounting points for assembly tools, for example programmable robots, although other assembly equipment and/or tools may be used.

In the example illustrated, preferably three inverted multi-axis industrial robots150attach to the underside of floor136and extend down below floor136as generally shown. The upper frame130precision mounting surfaces accurately and precisely position the robots150relative to the upper130and lower124frames and assembly cell center point260providing a high level of dimensional and locational predictability and repeatability in the initial installed position and orientation of robots150with respect to the assembly cell for programming and operation. Alternately, precision located mounting holes are provided in the upper frames130to accept modular robot mounting plates (not shown). The mounting plates, for example, can be connected to the robots at the integrator's (i.e. vendor/supplier) facility with easy and precise connection to the upper frames130when installed in the assembly plant.

In a preferred example not shown, tapered locating pins may be installed on the upper portions of the lower frame124and coordinate with apertures or other details in the mating upper frame130. The tapered locating pins may be used to guide and position the upper frame130into 3-dimensional X, Y and Z precision location relative to the lower frame124and then secured in place with large bolts, other fasteners or other securing methods known by those skilled in the art.

Lower124and upper130frames are preferably made from welded steel elements although other materials known by those skilled in the art may be used. It is understood that lower124and upper130frames may take other sizes, shapes and configurations than that shown consistent with the above description as known by those skilled in the art.

As best seen inFIGS. 2 and 3A, B, the power and controls for each robot150are preferably housed in control cabinets160secured to upper frame floor136as generally shown. Other positions of the cabinets160suitable for the application and number of robots150(or other assembly tools and equipment) for a particular assembly cell56known by those skilled in the art may be used.

Referring toFIGS. 4-8, an example of a modular application equipment (AE) pallet or support170is illustrated (three (3) shown inFIG. 5). As best seen inFIG. 5, in the example, AE pallet170includes a mounting surface or top174having a width176and vertical joists or supports180(three shown per pallet) as generally shown. AE pallets170may include a bottom182forming a rectangular pallet-like structure. AE pallet may further include a back panel (not shown) and a front panel (not shown). Although mounting surface174is shown as a top or upper surface, it is understood other mounting surfaces, configurations and orientations known by those skilled in the art may be used.

In the exemplary AE pallet170, mounting surface174is a rigid panel having a plurality of through holes or slots, mounting bosses, weld nuts and/or other features for mounting application equipment (AE)190suitable for the assembly operations in the assembly cell56and most preferably for a particular assembly tool, for example a robot150. For example, mounting surface174can be a rigid steel plate with holes positioned in a 100 millimeter grid pattern for ease of positioning and securing all types of AE devices190. In a preferred example, where three (3) inverted robots150are connected to upper frame130, three (3) AE pallets170are preferably used providing the respective AE device190needed to support the respective robot150assigned an assembly task. As seen inFIG. 5, three (3) different forms of AE devices190are illustrated. In the middle AE pallet170, a fluid storage and dispensing system194is secured to top174as generally shown. Consumable fluid materials such as sealants, adhesives, coolants and lubricants are common in vehicle body assembly lines. Although not necessarily consumable, coolant or lubrication fluids such as water are considered consumable materials for purposes of the invention.

The far right AE device170has a consumable materials fastener feeder198connected thereto. Such fastener feeders may include consumable rivets, weld studs, weld nuts, screws and other fasteners common to vehicle body operations known by those skilled in the art. The far left AE support170includes a third application equipment, for example a welding controller for a resistance spot welding of aluminum application. Other AE devices190needed to support common vehicle body (or other product) assembly operations may include equipment necessary to support welding operations including, but not limited to, resistance spot, seam, laser, brazing, piercing and clinching operations. Examples of consumables for seam or brazing operations may include welding wire or electrodes that are selectively fed by a feeder to the assembly tool in the assembly station as further described below. It is understood herein that reference of supply of consumable or other materials from the AE devices to the assembly tool, for example a robot, also includes the supply to any end effector or other tool connected to the assembly tool. Other AE devices190, and consumable materials used thereby, known by those skilled in the art may be packaged and secured to a respective AE pallet170. Although described as useful with robots150, it is understood that AE devices190can be used with other assembly tools and equipment needed to support assembly and manufacturing line processes and operations known by those skilled in the art.

Referring toFIGS. 5 and 6, one example of an AE pallet connector186is illustrated. In the example, AE pallet170includes hooks188rigidly mounted to two or more vertical supports180as best seen inFIG. 6. Exemplary hooks188laterally extend outward from vertical supports180and engage cooperating structures, for example slots144in a laterally outward facing surface142of upper frame130forming a localized lateral continuation of floor136as best seen inFIG. 7. Alternately, the coordinating mounting holes may be in the floor136.

Referring toFIG. 9, an alternate example of mounting AE pallet170to upper frame130is shown. In the example, AE pallet170is mounted atop upper frame floor136through mechanical fasteners as generally shown (space shown between170and136for ease of illustration). In this configuration, the width140of upper frame130may be increased (not shown) to accommodate the width176of AE pallet170while allowing adequate space for walkway210as described below. Other structures, orientations and fastening methods for removably mounting AE pallets170to upper frame130known by those skilled in the art may be used.

In the examples, AE pallet170is configured to form a pallet-like support structure for any AE device190to provide consumable materials, other materials, or services (for example electrical power, fluids or data) to the assembly line, preferably adjacent exemplary industrial robots150. In a preferred example, pallet170width176is approximately 36 inches. In a preferred example, the combined widths140of upper frame130floor136and width176of AE support are less than 96 inches which is the standard width of a commercial boxcar shipping container. Other widths140of floor136and AE pallet170may be used to suit the particular application and assembly line environment. It is also in the scope of invention that the widths can comprise two or more pieces for ease of shipping and then assembled at the system integrator or on site at the assembly facility.

The exemplary pallet170is preferably configured, oriented and adapted to be lifted, carried and elevated by a forklift common in assembly plants. In one exemplary use, the modular AE pallets170are shipped “empty” to a supplier/vendor responsible for providing AE devices190to support assembly operations in one or more assembly cells56along one or more assembly lines38-45. The vendor can design and package the AE devices190in the space provided by the modular pallet170, securely mount the AE device190to the top174and fully test and commission the operation of the equipment at the supplier's facility thereby providing tested and ready to use equipment on installation at the assembly plant. It is understood that AE devices190may be mounted in other orientations with respect to pallet170, for example connected to the underside of top surface and extending downward. Other mounting and orientations of AE devices190to pallets170known by those skilled in the art may be used.

As best seen inFIGS. 4A-D, the modular design of AE pallets170provides for several configurations depending on the assembly operations for a particular assembly station56. As best seen inFIGS. 3A and 4A-D, where an AE pallet170and AE device190is desired to be installed to upper frame130, a safety rail146, normally installed to upper frame surface142or floor136, is simply disconnected from upper frame floor136and mounted to rail connection points (not shown) on AE pallet170as generally shown. Securing AE pallets170and reconfiguring the AE devices190for assembly cell56can be done in a matter of minutes versus hours or days with conventional assembly systems.

Referring toFIGS. 5, 7 and 8, an example of a conduit200is shown. Conduit200includes one or more of cables, wiring harnesses and/or pipes,202,204and205positioned between the AE devices190and the assembly cell are shown. In the example, conduit200may be a single or multiple conduits/cables/pipes202,204and205, used to route, for example, an electrical and/or data cables202for the transfer of electrical power and information data from the control cabinets160to supply the necessary electricity and data to the AE devices190to, for example, power a fluid distribution pump194to supply pressurized adhesive or sealer to robot150or other assembly tools or cell equipment. As best seen inFIG. 8, conduit200may include a cable204connected between the AE device190and the assembly tool exemplary robot150to provide consumable materials and other materials, data and services to the assembly tool robot in order for the robot to perform the predetermined and preprogrammed assembly tasks in coordination with the application equipment190in the assembly cell.

In a preferred example, where a robot150uses consumable materials, for example rivets, screws, or weld studs, to perform the predetermined assembly task, conduit200may include a pipe205is connected to the AE device190and routed through or around the AE pallet170, under upper frame130, through or around robot wrist152to the end effector156for the routing of consumable materials to assist assembly operations for that particular assembly tool. For example, it is common along vehicle body assembly lines to install adhesives, sealants and weld studs to the partially completed vehicle body in assembly cell56. Where a robot150is tasked with welding operations, the fluid dispensing system194may provide water or other fluids to cool the equipment for continuous operation. Additional AE devices may be installed on the same AE pallet to further support, for example, a seam welding robot through feeding of consumable welding electrode through conduit200to support the welding operation. It is understood that conduit200could be a pipe or casing separate from the individual cables/wires and pipes described above, or may simple be the cables/wires and pipes themselves.

In the example where an AE pallet170includes fastener AE devices190, conduit200may include hoses or pipes for the transport of fasteners into the assembly cell. In a preferred example, AE pallet170includes one or larger routing apertures (not shown) in top174and open face178for the ease of routing conduit200laterally toward upper frame130. The assigned robot150or other assembly cell tools would include the appropriate coordinating and reciprocal connectors so conduits200and/or202,204and205can be rapidly connected for communication of consumable materials, data and other items on installation of the modular AE pallet170to upper frame130as described. Other communication lines, conduits and routing techniques and connections known by those skilled in the art may be used. For example, the conduit200may simply be routed around the AE pallet floor versus through apertures in the floor as described.

It is understood that conduit200may come installed with the AE pallet and AE device as transferred into the assembly facility or may be largely, if not wholly installed in the assembly station. In the latter example, the AE device190may have a short conduit or simply connectors on the AE device190so it can be rapidly connected and placed in communication with the assembly cell control cabinet and/or the assembly tool in the manners described. In combination of conduits200is also contemplated. For example, both the assembly station and AE device may have a conduit with coordinating connectors which are engaged on installation of the AE pallet to the frame. It is also contemplated that the AE pallet170comes “pre-wired” and includes coordinating connectors on the pallet170. For example, the pallet170may have common connectors or a bank of plugs wherein the AE device plugs into the pallet170. On installation of the AE pallet to the assembly frame, wires/cables and pipes preinstalled in the assembly station are routed and plugged into another bank of connectors/plugs which place the AE device190in communication with the assembly tool and control cabinets in the manners described. Other structures and methods of connecting the AE pallet and AE device in communication with the assembly station known by those skilled in the art may be used.

There are numerous advantages to the modular AE pallet system as described and illustrated. For example, if the mounted first AE device190fails and it is too time consuming or costly to repair or replace the first AE device190on site at the assembly line, the entire first pallet170can be disconnected and replaced with a replacement first modular pallet170with a pre-installed and tested replacement first AE device190with minimal assembly line downtime and logistical disruption. This modularity and plug and play connectively will greatly reduce critical downtime of the assembly line for repairs, replacement and time consuming maintenance of application equipment190.

The modularity also is a major advantage for vehicle model and other product changeovers requiring reassignment of a robot150assembly operation or other assembly line tools/equipment. For example, a second AE pallet170with a second AE device190suitable for the new assembly tool or operation can be quickly mounted to upper frame130through a forklift or existing gantry crane and connected to the retasked or new assembly tool through conduit200as described above. In a preferred example, the second AE pallet would be the same modular AE pallet170used with the first AE device, but having a different, second AE device190connected to it suitable for the alternate assembly operation by the assembly tool. It is contemplated that more than one type or form of modular AE pallet170may be used to accommodate the various AE devices190or assembly line operations.

The elevation of the application equipment190further removes such equipment from traditional placement on plant floor14and routing of the communication or support lines up to the inverted robots150which typically required dedicated frames to support and route the lines, for example hoses and fastener conduits.

In a preferred system10and application of AE pallets170and application equipment190shown inFIGS. 7, 8 and 9, the dimensional size of floor136and the placement of control cabinets160and application equipment190preferably provides for a walkway210along floor136longitudinally along upper frame130. In one example, this is advantageous for access and maintenance of systems in the control cabinets160and AE devices190positioned thereon or connected thereto. Further, as the AE device190which provides consumable items such as adhesives and fasteners to the assembly cell, these consumable materials need to periodically be replenished. Walkway210provides a pathway for operators (seeFIG. 8) to maneuver and restock these consumables for continuous assembly station operation. As an example shown inFIGS. 7 and 8, a drum of fluid can be raised by a forklift and installed atop floor136. A dolly or cart can be used by an operator to move and replace an empty fluid storage container for a fluid dispenser194. Where fasteners need to be replenished, an operator can manually carry a box of fasteners and load them in the application equipment hopper for future distribution to the robot150by the application equipment190and conduit200as described.

Referring toFIG. 4B, an example of a distribution deck212is shown. Distribution deck212is used to assist in the supply or replenishment of consumables, for example, adhesives, sealants, fasteners and other materials that are used by the various AE devices190mounted on AE supports170. In the example shown, deck212is positioned at one or both ends of an assembly line40-45(FIG. 1) and has a platform which is preferably directly adjacent and at the same elevation as floor136of the upper frame130and in the exemplary AE pallet floor174shown inFIGS. 4, 7 and 8. In the example deck212, consumables, for example 55 gallon drums of sealant216for use in fluid distribution device194, would be raised up to platform214by a forklift or other device and deposited on the platform. Operators can manually, or through aid of a moving device, move by hand cart the consumables deposited on deck212along path210to the appropriate AE pallet170where the consumables are needed. This is very advantageous for continuous operation of the AE devices190and assembly station56. The position of the AE devices190, consumables216and workers above the assembly cell56for this work is very advantageous for plant logistics, efficiency and safety. Other methods of depositing the consumables216on platform214and movement along path210may be used as known by those skilled in the art.

Referring toFIG. 1, in a most preferred example, a distribution deck212would be provided at one end of each assembly line40-45adjacent to the material load and sequence area30. In one example, distribution deck212may be continuous and span several or all assembly lines40-45or be individual to each line where consumables are needed to support assembly operations. The consumables216would travel the least distance from the material entry area20to the assembly line and thus further simplify assembly plant floor congestion and logistics. Other configurations and locations of distribution deck212known by those skilled in the art may be used without departing from the present invention. It is further understood that distribution deck212may serve other purposes than receipt of consumable materials as known by those skilled in the art.

Referring toFIGS. 10 and 11, an example of an aspect of system10includes modular assembly tool (AT) platforms or trays220to provide assembly tools or other assembly equipment, for example programmable multi-axis robots226, additional AE devices190and associated accessories or devices used thereby. In one example of an AT platform220, modular robot platforms220are illustrated (two shown inFIG. 10, four shown inFIG. 11) at floor level14of the assembly cell56. In the exemplary AT platforms220, a floor-positioned industrial multi-axis robot226having a principal axis of rotation230(shown inFIG. 13) is mounted to a base236. In a preferred example, base236includes a base plate having precision, most preferably equally spaced, mounting points or holes240for mounting the robot226. The exemplary base plate is preferably mounted to frame rails246that extend laterally outward from assembly path60as generally shown. Rails246preferably also include precision positioned mounting points250, for example holes, along the length of the rails. The exemplary base plate and rail mounting points provide predetermined, highly predictable and repeatable mounting points in the Z, Y and Z dimensional coordinates for the robot relative to the rails246.

In a preferred application, rails246are rigidly connected to a continuous product conveyor or other equipment positioned along the assembly line or path60relative to the assembly station reference point260as best seen inFIG. 11. Connection of the modular AT platform220including exemplary frame rails246can be made through use of rigid brackets254mounted in holes252as generally shown or other connection devices and configurations known by those skilled in the art. In a preferred example, conveyor rail holes252are equally spaced apart and generated with close/small dimensional tolerances for accuracy and precision mounting of the AT platforms220. Mounting points252may include other structures to securely connect AT platform220to the conveyor or other assembly station structure for the particular application.

Although platform220base is shown including rails246, it is understood that the frame or support structure can vary depending on the assembly tools and AE equipment and application. For example, support220may include a pallet-like structure as170so the AT platform220can be transferred and moved to the line by a forklift. The exemplary base plate may include a heavy steel plate with a grid of equally spaced holes 100 millimeters (mm) for ease of mounting the assembly tools and AE devices. The plate may be supported by rails246or other structures known by those skilled in the art. It is understood other platform220constructions to position and mount platform220to the conveyor or support structure110can be used as known by those skilled in the art.

As discussed above for the inverted robots150, the exemplary precision base plates236, rails246and mounting holes240,250and252provide for accurate, precise and repeatable X, Y and Z coordinate dimensional positioning of the robot226relative to the known assembly cell center point260and other assembly station equipment thereby facilitating rapid placement, plug and play and programming of the exemplary robots226for assembly operations once installed at the assembly plant. AT platform220may be connected to mounting plates that are installed in the assembly plant floor in a similar manner to those described for mounting assembly station lower frames124described above and below forFIG. 15.

Modular AT platforms220may further include the necessary control cabinets156to power and communicate programs and data with the respective assembly tools and AE devices190installed on support220. Similar to the modular AE pallets170and AE devices190discussed above, one or more of the assembly tools, AE devices190and control cabinets can be pre-installed on base plates236and/or frames/platforms246at the assembly tool or other supplier's facility and be fully commissioned/tested before shipment to the system integrator or directly to the assembly plant for installation. Similarly as described for AE pallets170, the AT platforms220can be pre-wired and cabled as necessary with a conduit200for plug and play installation and operation at the assembly facility as similarly described above. The AE devices190can supply consumables and other materials and functions to the assembly tools, for example robots226, as described for AE pallets170.

The preferably self-contained, operational and initially tested/commissioned modular AT platforms220and equipment thereon can be transported to the assembly line, rapidly secured and connected to the existing assembly station equipment and control system in a plug and play manner as generally described for AE pallets170and AE devices190. This greatly reduces the time and effort to locate, program and calibrate the assembly tool into the assembly station for rapid, small/close dimensional tolerance production operation.

It is understood that any control cabinets and AE devices required for AT platform220can be mounted to the base236or other structure described above or can be stand alone devices that are separately and independently positioned and secured in proximity to the AT platform assembly tool. In one example where robots226are tasked with spot welding functions, an example of an AE device190can be automated weld tip dressers (not shown) precisely positioned on a larger base plate236or frame relative to the robot. For example, at scheduled intervals, the robots226can be programmed to run a maintenance cycle wherein the robots position the end effector spot weld gun weld tips in engagement with the weld tip dressers to condition the weld tips for optimum and continuous operation of the assembly cell. Other AE devices190discussed above, and methods of coordinating, integrating and connecting and connecting these devices with assembly tools known by those skilled in the art may be used.

Referring toFIGS. 12 and 13, another aspect of an example of system10includes a modular protective fence or guard270which assists in preventing personnel from entering assembly station56during operation. In the example, fence270includes a first frame272and a second frame273as generally shown. In a preferred example, each frame273and273includes a vertical post274, an upper support276, an upper rail278and a lower rail280. In the example fence270, one or more front panels286extending along parallel to assembly path60and side panels connected between the upper278and lower280rails are used. In a preferred example, each fence frame is rigidly mounted to and cantilevered from the assembly station lower124and upper130frames as generally shown. This advantageously places the lower rail280and side panels290a predetermined height294above the plant floor14negating traditional mounting structures to the plant floor14. This is advantageous for faster installation, maintenance and repair and cleaning of the assembly plant floor. This is further advantageous over conventional protective guards further providing for a modular plug and play assembly system with minimal requirements or reliance on the existing assembly plant infrastructure.

Front286and side290side panels can be made from steel, aluminum or other materials, for example transparent materials like polycarbonate, forming a grating or barrier to keep personnel and objects from unauthorized entry into the assembly station. Other materials, sizes, shapes and configurations of the panels and frames known by those skilled in the art may be used.

In a preferred application of modular fence270, the front panel286is slidingly mounted in guides296and connected to a retractor device300. An example of a retractor device300includes an electric motor302mounted to upper frame130, a cable304and a stationary pulley308as generally shown. The retractor is selectively operable by an operator or control system (not shown) to raise the front panel from a first lower position310proximate floor14to a raised upper position316. Upper position316is preferably of sufficient height such that operators and other equipment, for example forklifts, can enter assembly cell56and access and move assembly tools and other equipment to and from assembly cell56as necessary in the normal operation of the facility.

As best seen inFIG. 12, in an application of fence270with use of AT platforms220, the guides296are preferably positioned laterally outward from the assembly tool robots226and laterally inward from control cabinets156and AE devices190as generally shown. This provides access to the assembly tool controls and AE devices190to, for example replenish consumable materials provided to the assembly tools by the AE devices190. Other positions of fence front and side panels known by those skilled in the art are within the present invention.

In a preferred application and operation of fence270, the front panel286is normally positioned in the lower position310when the assembly station56is energized or in active assembly operations. When maintenance or access to equipment inside of assembly cell56is required, retractor device300can be engaged manually or through signals received from a local or central controller (not shown), to raise front panel286to the upper position316allowing personnel and equipment easy access into the cell56without the need for disassembly or partial removal/relocation of traditional protective fences or guards. It is understood that different configurations of fence280can be made to suit the particular assembly cell or line and known by those skilled in the art. Further, retractor300can take other forms and features known by those skilled in the art. For example, front panels can be manually raised and locked into place with pins or other devices and then manually lowered to continue assembly operations.

Referring toFIG. 14a flow chart of an exemplary process400to build and install AE pallets170in an exemplary robot assembly tool application is shown. In the exemplary process, at step410it is determined the number and specific assembly operations that will be performed in one or more assembly stations56, for example exemplary vehicle body assembly operations executed by industrial robots150with various end effectors for a variety of assembly operations. A plurality of modular, and preferably identical, AE pallets170are fabricated having the structural and spatial features described in the examples above in step420. In step430, the modular AE pallets170are shipped “empty” in large quantities to a respective vendor for installation of an AE device (or devices)190by the vendor for a particular robot150or other assembly tools.

In an optional step435, the installed AE device190on the modular pallet170is pre-wired/pre-cabled with conduit200including power and data communication lines206appropriate for the assembly station, assembly tool and/or assembly operation and mated with coordinating connectors for attachment with connectors on the control cabinets, the robots150, other assembly tools or other assembly cell equipment. The AE device190is then preferably tested/commission at the vendor or system integration to ensure proper operation before shipment to the assembly plant. In some AE devices190, advanced testing and pre-programming of software can be performed at the vendor with minimal or no modifications and adjustments being necessary at the assembly plant for volume production.

In exemplary step440, the modular AE pallet170and installed AE device190is shipped to an intermediary system integrator facility, or alternately directly to the assembly plant, and matched with the prefabricated assembly scaffold frame120, conveyors, non-model specific equipment, for example pre-installed robots150, and selected model-specific equipment assigned the assembly task supported by the application equipment190. The pallet170may be elevated into position proximate upper frame130and floor136by a forklift or other lifting mechanism. The modular pallet170is then engaged to the upper frame130in the examples described, for example engagement of hooks188with coordinating slots144in upper frame130.

In exemplary step450, the application equipment conduit200is routed and the prewired or pre-cabled lines202,204,205and/or206are connected to the pre-wired or pre-cabled robot150, control cabinets or other cell equipment for rapid install, communication and operation of the assembly cell56. In an optional step (not illustrated), consumables216are transferred to and placed on upper frame(s)130through distribution decks212to supply the respective AE devices190with needed materials to support the predetermined assembly operations.

In an optional step460, on a failure or required heavy maintenance of the AE device190installed on the modular AE pallet170, the entire pallet170is preferably disconnected from the control cabinet, robots and upper frame130and quickly replaced with another pallet170with replacement or alternate AE device(s)190. This equally applies where a product model changeover occurs and/or robot tasks changed. The existing AE pallets170with AE device190is disconnected and swapped out with an alternate pallet170having the appropriate AE device190for the new assembly task.

As described, the process400may equally be applied to AT platforms220, or the AE devices190used therewith as described. For example, if a robot assembly tool fails or needs heavy maintenance, the modular AT platform220can be disconnected and replaced with a new or alternate assembly tool and AE devices190as required, and connected to the conveyor or other equipment as described above. The mounting points of the base236, rails246and conveyor provide for rapid reconnection of a replacement AT platform220relative to the assembly station and/or assembly station reference point260thereby minimizing reprogramming or calibration of the new assembly tool.

Referring toFIG. 15an exemplary method500of assembling or installing a modular vehicle assembly system10is illustrated. In the example, prefabrication of system10infrastructure such as frames120, conveyors or transports48, assembly tools for example robots150/226and other unique tooling is assumed to be already complete, but understood can vary as known by those skilled in the art.

In an initial step not shown, the centerline of assembly line60is preferably determined. In one example, the centerline is determined from existing X, Y and Z dimensional coordinate reference points defined by the assembly plant. An assembly cell reference point260may be determined as described above.

In the example, in step510lower frame124mounting plates are secured to the assembly plant floor14in predetermined locations relative to the assembly line60, assembly center line and/or assembly cell centerpoint260as generally described and illustrated. In step520, the lower frames124are removably secured to the mounting plates on both sides of the assembly line path60. The attachment points where the lower frames attach to the floor mounting plates are preferably laterally spaced from the assembly line centerline and longitudinally positioned along the assembly line at predetermined locations. In an alternate method (not shown), the lower frames124are mounted to the floor at predetermined locations which then the below conveyor is positioned and mounted with respect thereto. The assembly cell reference point260may then be established based on the installed frame and conveyor.

In step530the vehicle conveyor system along assembly path60is installed as well as any framing needed where a return conveyor along a return upper path84is installed. In an optional step535where an overhead conveyor is used as generally shown inFIG. 3B, a transverse tooling conveyor112may be installed. In a preferred example, the lower frames124, and conveyors50/52/90/110defining respective assembly paths60/78and84, tooling conveyor112(if an overhead conveyor system) and protective fences280are considered to be vehicle non-model specific equipment. In other words, these devices are preferably wholly standard and used for all vehicle models or other products to be assembled.

In exemplary step540, the assembly station upper frame130is installed and secured atop the lower frame124. In one example, the assembly tool industrial robots150and control cabinets160are pre-installed on the upper frame130as a unit by a vendor prior to delivery to the assembly cell and prior to securing it to lower frame124. In a preferred example, the upper frames130, although may all be modular, identical and standard in construction, are shipped “empty” to a vendor for installation of model-specific equipment, for example preprogrammed assembly tool robots150and appropriate control cabinets160. The vendor, similar to that described for AE pallets170and AE devices190, installs and commissions the assembly tools and/or model specific equipment on upper frame130(or as much as practically possible depending on the equipment and application) at the vendor or system integrator's facility prior to shipment to the assembly facility for installation into the assembly station56and final commission for production assembly. Alternately, the robots150and control cabinets160may be installed following installation of the upper frame130onto the lower frame124in the assembly facility or in another sequence as known by those skilled in the art.

In exemplary step550the AE pallets170with preinstalled and commissioned vehicle/product model specific AE devices190are transported to the assembly facility and secured to upper frames130, coordinated with the appropriate control cabinet, and electronically connected to the robot150, end effector or other assembly cell tools and equipment as generally described above. The same or similar process would be carried out for any model specific modular AT platforms220for a pallet-style conveyor system (FIG. 2) as generally described above.

In exemplary step560, unique vehicle or product model specific tooling trays, tooling, fixtures and other equipment are delivered and installed to complete the operational assembly station equipment.

In exemplary step570, any remaining protective fences270to accommodate the model specific equipment are installed and/or enabled. It is understood that depending on the assembly cell, part or all of the protective fence or fences270may be installed earlier as described or where appropriate in the cell assembly process.

Referring toFIG. 16another exemplary aspect of the invention is illustrated. InFIG. 16an exemplary process, business method or solution600for purchasing/sourcing, fabricating and installing equipment for a vehicle body or other product assembly line is illustrated. The exemplary process is particularly useful with the modular system10described above, but may be used with other assembly operations for other products. It is understood the method600can be used for products other than vehicle body assembly as known by those skilled in the art.

In the example, step610establishes high level assembly plant parameters including plant size and target vehicle (or other product) throughput (vehicles/products per hour, shift, week and/or month or other periods or variables).

In step620, the assembly plant is preferably simulated three-dimensionally through CAD-CAM or other simulation tools to establish the number of assembly lines and throughput and/or efficiency of each individual assembly line. It is understood this step could be done manually or through other conventional processes and mechanisms known by those skilled in the art.

In step620, the assembly operations and equipment necessary for completing the assembly tasks are determined for each assembly line40-45. For each assembly line, the equipment is initially determined to be vehicle/product non-model specific or vehicle/product model specific. In the example, equipment is vehicle non-model specific if the equipment is useful in assembly regardless of which vehicle model or body style is being assembled. An example of vehicle non-model specific and model specific for the described system10is:

Conveyor (overhead-style90or pallet-style106);Both along assembly path60and any return path84;Base conveyor pallets106or suspended carriages;Component and subassembly delivery devices (in system10provided by carts62or carriage racks94);Generic/standard component trays, for example steel panels with precision cut holes in a 100 millimeter (mm) grid pattern for precision positioning and securing model specific detail fixtures or holders for individual components or subassemblies to be assembled;Lifting mechanisms within assembly cell for use with pallets or suspended carriages;Buffer conveyor zones along and/or laterally between assembly lines;

Carriage/pallet elevator device to move from lower path60to upper path84;

Robots150/226that are not preprogrammed for particular assembly operations;

Modular AT platforms220(without robots or control cabinets or accessories); and

Partial or all protective fencing270.

Vehicle Body Model Specific (MS):

Unique tooling and fixtures for conveyor suspended carriages and pallets;

Unique tooling and fixtures for to-be-assembled component panels/trays

Unique tooling and fixtures for transverse tooling conveyor112;

Robots150/226, robot controls and control cabinets160and preprogrammed and stored software for particular assembly tasks/operations;Robot end effectors156;Any portion of conduit200including pre-plumbing, wiring, cables, pipes and connectors of robots/assembly tools to accept and connect to AE devices190and consumable materials;

AE devices190; andAny portion of conduit200including pre-plumbing/wiring, cables, pipes and connectors on AE pallet170and AT platforms220.
It is understood that variations whether equipment is initially designated as non-model specific or model specific may occur depending on the product, assembly application and operations within an assembly cell.

In step630, in a preferred example, the non-model specific equipment is placed out for competitive bid contract and awarded to a single or minimum number of vendors. In the example for system10, all vehicle non-model specific assembly equipment for all assembly lines may be sourced to one vendor. This is possible in part as the non-model specific equipment is standard and/or modular and at least partially pre-designed. This reduces and minimizes prior processes which took months and months to largely, if not wholly, custom design the non-model specific infrastructure and equipment for every assembly plant. In system10, since the non-model specific equipment is preferably modular and predesigned, the process to bid and award happens far more quickly than the conventional process.

At this optional point in time for step635, fabrication can begin on the system10modular non-model specific infrastructure and equipment.

In step640, based on the predetermined and preferably already designed modular, non-model specific equipment, the vehicle model specific assembly equipment is specified and competitively placed out for supply bid contract. In a significant advantage over conventional processes, the bids for the model specific equipment can go out much faster, possibly many months faster, as the non-model specific designs, or a great many portions thereof, are already complete. In one example in step640, supply contracts for the model specific equipment for each assembly line40-45, or combinations of assembly lines, may be awarded to other integrators/vendors. During this period640, the non-model specific equipment is already partially or wholly awarded and preferably fabrication already underway.

In a preferred example of step640, each winning model specific vendor would be responsible for the required product throughput performance for the awarded lines. It is understood that steps635and640can occur simultaneously or even switched depending on how long the lead times are for effective management of the quotation process.

In exemplary step650, the awarded model specific equipment is designed. During this period, fabrication of the awarded non-model specific in step635continues. Where appropriate, in step655installation of the completed non-model specific equipment can occur at the assembly facility for initial commission. Where non-model specific equipment is to be delivered to the model-specific vendor, for example empty upper frames130, AE pallets170and AE platforms220, these can be shipped to the model specific vendors in step660.

In exemplary step670, the model specific equipment is fabricated and commissioned/tested. In a preferred example respecting upper frames130, AE pallets170, AE supports220and necessary AE devices190are installed, wired and plumbed with the appropriate cables and harnesses and tested at the vendor's facility as generally described above.

In exemplary step680the tested vehicle model specific equipment arrives and is installed at a system integrator or directly at the assembly plant. In the example of the AE pallets170with installed AE devices190, the AE pallets are lifted into position and quickly secured to upper frame130as previously described. The conduit200, which may include one or more of202,204,205and206are quickly and readily connected to the control cabinets, robot150(or other assembly tools or equipment) and coordinated with the equipment in the assembly station for rapid and already proven operability avoiding may problems and delays in conventional systems. This similarly occurs for modular AT platforms220as previously described. Other model-specific equipment is fabricated, tested and installed in the same manner. If the particular assembly plant or equipment warrants it, the fabricated modular upper frame130may have been shipped to the model-specific vendor. In such an instance, the robots150, AE pallets170, AE devices190, and control cabinets160may arrive to the assembly plant and be installed as a completed unit atop the lower frames124. Alternately, the separate AE pallets170shipped to the assembly facility, but can be installed after the upper frame and robots are installed on the lower frames124.

In one optional step (not shown), on initial installation or once production assembly begins, for example if a particular first AE device190fails or needs maintenance or refurbishment, the entire first AE pallet170or platform220that the respective failed first AE device190or assembly tool is secured to can be quickly disconnected and removed from upper frame130or conveyor and replaced. In one example, new (or refurbished) and tested replacement first AE device or alternate second AE device190preinstalled on an alternate or second AE pallet170can be raised, secured to upper frame130and connected to the control cabinet, robot and assembly cell in a matter described above.

Once operational, in an optional step not shown the individual assembly lines40-45throughput requirements are monitored and enforced on an assembly line-by-line basis, and the respective equipment vendor which supplied the particular model specific line and/or equipment is held accountable to meet the predetermined performance targets, to ensure the overall assembly line and assembly plant vehicle/product throughput specification is achieved.

For all of the described and illustrated methods400,500and600, it is understood that additional steps, fewer steps and reordering of the above steps consistent with this technical disclosure can be made to suit the particular application and performance specifications as known by those skilled in the art without deviating from the present invention.

Although described individually, the modular AE pallets170, AT platforms220and fence270may all be included, or separately included in various combinations to suit the particular application, to form the system10structure and methods as described and/or illustrated herein.