Abstract:
The present invention generally relates to fixtures and methods for assembling automotive instrument panels. Some embodiments include a means for locating an instrument panel in a lateral direction and in a selected rotational direction. Some embodiments also include a means for locking the panel in specific desired rotational position. Furthermore, some embodiments may accommodate a wide variety of panel designs having variable lengths.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    A. Field of Invention 
         [0002]    The present invention generally relates to devices and methods for assembling automotive instrument panels. 
         [0003]    B. Description of the Related Art 
         [0004]    It is known in the automotive manufacturing arts to use fixtures for holding and positioning instrument panels during assembly processes. Prior fixtures had limited capacity for locating the panel in a lateral direction. Thus, positioning and handling the panel is difficult and often requires two or more people. Furthermore, prior fixtures have limited rotational controls, and often did not adequately prevent the panel from moving rotationally during assembly. Thus there is a need in the art for a fixture that overcomes these and/or other deficiencies. 
       BRIEF SUMMARY OF THE INVENTION 
       [0005]    The present invention generally relates to an automotive instrument panel assembly fixture, comprising: a frame adapted to support an automotive instrument panel assembly; an opposing pair of panel assembly support cones comprising a first cone and a second cone and defining a longitudinal axis, and the cones each having a conical face opposing that of the other, and each having a flat face in vertically supported and rotatable relations with the frame, wherein the opposing pair of cones is adapted to engage a panel assembly at opposing ends of the panel; the first cone further comprising a movable panel engagement pin, wherein the panel engagement pin has a range of motion coextensive with the longitudinal axis; the second cone further comprising a panel assembly engagement key adapted to fix the rotational orientation of an instrument panel assembly relative to the key, and the key being in an adjustable fixed relation with the second cone, the flat face of the second cone having a plurality of indexing holes evenly spaced in a concentric circular pattern, wherein the flat face of the second circular cone has a plurality of ball plungers evenly spaced in a concentric circular pattern; an indexing member parallel to the flat face of the second cone, the indexing member having a plurality of holes evenly spaced in a concentric circular pattern the holes adapted to each receive a ball of a ball plunger in an indexing relation, wherein the indexing plate additionally includes an indexing hole adapted to align with any of the indexing holes defined by the flat face of the second cone and adapted to receive an indexing pin, the indexing pin holding the second cone in a fixed indexing relation to the indexing plate; and a rotatable crank member in a fixed relation with the second cone and adapted to cause rotation of the second cone about the longitudinal axis. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The invention may take physical form in certain parts and arrangement of parts, embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein: 
           [0007]      FIG. 1  is a drawing of a pair of opposing cone members; 
           [0008]      FIG. 2  is a drawing of a cone member having a variable stroke plunger; 
           [0009]      FIG. 3  is a plan view of the faces of a cone member; and 
           [0010]      FIG. 4  is a cross sectional view of an assembly. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0011]    Some embodiments relate to fixtures for assembling automotive instrument panel assemblies or related methods. According to some embodiments such a fixture can include a frame adapted to support an instrument panel assembly, a means for fixing the lateral position of the assembly, and a means for fixing the rotational position of the assembly about a longitudinal axis. According to some embodiments, the fixture can rotate the assembly incrementally using one or more indexing means. Furthermore, according to some embodiments the fixture is adapted to fix the lateral position of the assembly at any point in a continuous range of lateral motion. 
         [0012]    A frame can take any of a wide variety of forms provided it is capable of supporting the load of an instrument panel assembly and other structures of the fixture. For instance, in some embodiments the frame comprises tubing having a rectangular cross section. Suitable tubing can have a variety of cross sectional dimensions such as, but not limited to, from about 0.5 inch to about 4 inches square. Furthermore, the frame can comprise any of a wide variety of materials including, but not limited to, steel, stainless steel, aluminum, aluminum alloy, organic polymer, or polymer composite materials. In some embodiments, the frame comprises a generally rectangular base having a pair of vertical support structures spaced apart and providing space for receiving an instrument panel assembly. Furthermore, is in some embodiments the frame can include a plurality of casters for conveniently positioning the device. Some embodiments can additionally include locks for the casters so that the position of the device can be fixed. 
         [0013]    A means for fixing the lateral position of an instrument panel assembly can comprise a variety of components. According to some embodiments the means can comprise a pair of opposing conical structures mounted on opposing sides of the frame and vertically supported by the frame and defining a longitudinal axis, and further defining a working width for receiving an instrument panel assembly. Such conical structures can be in a rotational relation with the frame so that the conical structures are free to rotate while being vertically and/or laterally supported. Furthermore, the cones can comprise, for example, solid metal formed by appropriate machining processes, such as lathing, milling, drilling and the like. 
         [0014]    A first cone can comprise a flat circular face generally facing a first side of the frame, and further comprise a conical face. The conical face may be truncated so that it does not come to a point, but rather defines a smaller flat face parallel to the other flat face. Furthermore, the first cone can define a bore passing through the center of mass of the cone and extending from the larger to the smaller flat face. Thus, the bore can be centered on the longitudinal axis. The bore can receive a means for adjusting the working width. For instance, in some embodiments, the bore can receive a plunger, a variable stroke plunger, a screw or the like or any combination thereof. According to such embodiments, the plunger&#39;s range of motion is coextensive with and along the longitudinal axis. 
         [0015]    A second cone can be shaped similar to the first but oriented so that its flat face is directed toward the second side of the frame and its conical face is directed toward that of the first cone. The second cone can have at least one bore passing at least partially through the center of mass of the second cone and extending along the longitudinal axis. The smaller flat face can include a key member for receiving an instrument panel assembly and fixing its rotational orientation relative to the second cone. The specific shape, size and position of the key member are dictated by the configuration of the instrument panels that the fixture is designed to receive. In some embodiments the key member can occupy a bore defined by the second cone along the longitudinal axis and extending from the smaller flat face. Furthermore, the key may be permanently fixed or adjustable. 
         [0016]    With further regard to the second cone, the larger flat face of the second cone can include a plurality of indexing members for indexing the rotational position of the second cone. In some embodiments, the indexing members can include one or more ball plungers. For instance, the second cone can be drilled to receive ball plungers arranged in a circular pattern concentric with the bore of the cone. According to such embodiments an indexing plate is advantageously parallel to the larger flat face and supported by the frame in a fixed relation. The indexing plate can be spaced apart from the face by a distance less than that by which the balls of the ball plungers protrude beyond the face. Furthermore, the indexing plate can define receiving holes adapted to mate with a protruding portion of the balls. In some embodiments the balls each simultaneously mate with receiving holes of the indexing plate. 
         [0017]    In some embodiments, the larger face of the second cone can be additionally drilled to define indexing holes adapted to receive a removable indexing pin. The indexing holes can be arranged in a concentric circle having a diameter larger than the concentric circle defined by the ball plungers. Furthermore, the indexing holes may be adapted to align with a complementary indexing hole defined by the indexing plate. Accordingly, an indexing pin can be inserted through the indexing plate and seat in an indexing hole defined by the second cone. Thus, the rotational position of the second cone can be securely fixed relative to the indexing plate, and can only be moved by first removing the indexing pin. 
         [0018]    In some embodiments, the second cone can also include a bore defined by the larger face. The bore can be adapted to receive, for instance, a drive shaft in a fixed relation. Accordingly, the second cone can be rotated about the longitudinal axis by rotating the drive shaft. Furthermore, in some embodiments the drive shaft additionally passes through a bore defined by the indexing plate. Thus, the drive shaft can be vertically supported by the indexing plate. One of skill in the art will recognize that a wide variety of methods and structures are known for rotating a drive shaft. Some structures include gears for gaining a mechanical advantage and reducing the force required to rotate the shaft. Some structures also include a crank handle for manually rotating the drive shaft. In some embodiments a ratcheting member may be included to force the fixture to rotate in a single direction. Moreover, such ratcheting members can be reversible or entirely disengageable. Still other embodiments can include a motor for automating rotation of the drive shaft. Some embodiments may include some or all of the foregoing structures related to rotating the drive shaft. 
         [0019]    Some embodiments can operate as follows. A user can insert the indexing key through the appropriate hole in the indexing plate and engage an aligned indexing hole in the second cone. Accordingly, the rotational position of the second cone is fixed relative to the frame. However, the first cone is free to rotate about the longitudinal axis. The user can place an automobile instrument panel between the opposing cones of the fixture, and engage the key member of the second cone with the panel, thereby holding the panel in place while the variable stroke plunger of the first cone is adjusted to engage the panel. The user then simultaneously aligns the free end of the panel with the plunger, and adjusts the position of the plunger until it engages the panel. The panel is now fixed laterally and rotationally. The panel can be rotated by removing the indexing pin and turning the drive shaft. As the drive shaft turns, the seated balls compress their respective springs and recede into the flat face thus allowing the cone to rotate. The cone continues to rotate until the balls engage the next receiver holes in the indexing plate. The user can continue to rotate the panel until the desired orientation is achieved for assembling or otherwise working on the instrument panel. When the desired rotational position is achieved, the user can then reinsert the indexing pin to fix the position while he works on the panel. 
         [0020]    Turning now to the Figures,  FIG. 1  is a drawing of a pair of cones similar to those described herein. The cones  100  are disposed in an opposing relation with their smaller flat faces directed toward each other. Furthermore, the cones  100  define a longitudinal axis  110  comprising a straight line. The space between the cones  100  can be adapted to receive an instrument panel. First cone  101  defines a bore  130  passing through the cone from one flat face to the other and being coextensive with the longitudinal axis. The second cone  102  defines a first bore  132  coextensive with the longitudinal axis and adapted to receive a key member. The second cone  102  also defines a second bore  134  adapted to receive a drive shaft. 
         [0021]      FIG. 2  is a more detailed drawing of the first cone  201 . The cone  201  includes a variable length plunger  220  having a plunger  210  and a handle  230  for extending and retracting the plunger  210 . The plunger&#39;s  210  range of motion is along the longitudinal axis  240 . 
         [0022]      FIG. 3  shows the two flat faces of the second cone  300 . The smaller flat face  310  is shown defining a bore opening  312 . The large flat face  320  is shown defining a bore opening  350  as well as a plurality of indexing holes  330  arranged in a circle  332  concentric to the bore opening  350 . The larger face  320  is also shown receiving a plurality of ball plungers  340  arranged in a smaller concentric circle  342 . Furthermore, each ball plunger  340  is aligned with both the bore  350  and a corresponding index hole  330  along ray  360 . Accordingly, when a ball plunger  340  seats in a receiving hole exactly one index hole  330  is simultaneously aligned with the index hole of the indexing plate. 
         [0023]      FIG. 4  is a cross sectional view of an assembly  400  comprising the second cone  410 , the indexing plate  420  and drive shaft  430 . According to  FIG. 4  the second cone  410  defines an indexing hole  416 A, which is aligned with indexing hole  422  of the indexing plate  420 . An indexing pin  440  is shown installed through the indexing hole  422  and in indexing hole  416 A. An opposing indexing hole  416 B is also shown in the second cone  410 , but since it is not aligned with the indexing hole  422  of the index plate  420  it cannot receive a pin and is therefore shown empty. A pair of ball plungers  450  are also shown installed in the second cone  410 . The ball plungers are installed in holes  414 , and comprise a spring  454  and a steel ball  452 . As shown, the ball plungers  450  are engaging the index plate  420  at ball seats  424  defined therein. Thus, as the index plate  420  rotates the balls  452  compress the springs  454  and retract into the holes  414 . When the next seat  424  is properly aligned, the balls  452  spring back out and engage the seats  424 . A drive shaft  430  is shown installed in the second cone  410  at bore  412 . As shown, the drive shaft  430  is in a fixed relation to the cone  410 , such as a press fit. Furthermore, the drive shaft  430  is shown passing through a hole  426  defined by the index plate  420 , but the drive shaft  430  is not attached to the plate  420 . Thus, when the drive shaft  430  rotates, it causes the cone  410  to rotate, but the plate  420  remains stationary. The drive shaft  430  is also shown in alignment with the longitudinal axis  401 . The assembly  400  further includes a hand crank  470  having a grip  472  for manually turning the drive shaft  430 . Although not shown, the assembly can also include gears, for instance, for providing a mechanical advantage, a ratcheting structure or any other appropriate structure. 
         [0024]    The embodiments have been described, hereinabove. It will be apparent to those skilled in the art that the above methods and apparatuses may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.