Abstract:
A method and apparatus for simultaneously installing multiple component parts. The apparatus having a carriage shiftably coupled to a supporting surface, a component part carrier for selectively holding and releasing a plurality of component parts, and a vacuum source circuit providing a vacuum attachment force for holding the component parts to the component part carrier. The process, including the steps of contacting a plurality of part receivers with a plurality of component parts, actuating a vacuum source to thereby temporarily attach the component parts to the part receivers by a vacuum attachment, translating the component part carrier to position the component parts in registry with part reception sites in a platform, and at least partially discontinuing the vacuum attachment force to thereby release the component parts from the part receivers.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention concerns a method and apparatus for simultaneously installing multiple component parts. The invention further concerns a method and apparatus for simultaneously installing multiple flexible sealing members in the floor of a vehicle body traveling along an assembly line.  
           [0003]    2. Description of the Prior Art  
           [0004]    During assembly, many vehicles, particularly mini-vans and SUV&#39;s, require a plurality of flexible sealing members to be installed in the vehicle floor. These sealing members are placed in cavities in the floor pan where the vehicle seats are coupled to sub-floor anchoring devices. The sealing members act to inhibit the flow of air and debris from below the vehicle floor into the vehicle cabin.  
           [0005]    In the past, flexible sealing members were manually installed, one-at-a-time. This installation method required an assembly line worker to crawl into the vehicle cabin and stoop over while installing the individual sealing members. Moreover, the continuous translational movement of the vehicle body along the assembly line inhibits the use of stationary installation devices.  
           [0006]    Thus, prior methods of installing sealing members consumed a considerable amount of time due to the manual, one-at-a-time placement of the members. In addition, prior methods of installing sealing members placed physical strain on assembly line workers because the workers were required to stoop over for extended periods of time. Further, prior methods of installing sealing members were dangerous because they required the worker to enter and exit the vehicle body while it was on the assembly line.  
         SUMMARY OF THE INVENTION  
         [0007]    It is accordingly an object of the present invention to provide a method and apparatus for simultaneously installing multiple component parts in a platform, especially a moving platform, thereby reducing the time required to install the component parts.  
           [0008]    It is further an object of the present invention to provide a method and apparatus for simultaneously installing multiple component parts which reduces strain on the human body.  
           [0009]    It is still further an object of the present invention to provide a method and apparatus for simultaneously installing multiple component parts in a vehicle on an assembly line which does not require the worker to enter and exit the vehicle, thereby reducing the risk of injury to the worker.  
           [0010]    It is another object of the invention to provide an apparatus capable of movement complemental or corresponding to the movement of the receiving platform, whereby production on an assembly line will not be slowed or otherwise inhibited while the component parts are installed.  
           [0011]    In one embodiment of the present invention, an apparatus for installing multiple component parts is provided. The apparatus comprises a carriage, a component part carrier, and a vacuum source circuit. The component part carrier has a plurality of part receivers positioned in substantially fixed spatial relationship to one another. Each of the part receivers is adapted for selectively holding and releasing a respective component part. The vacuum source circuit is fluidically connected to the part receivers and comprises a vacuum source and a switch. The switch is selectively actuatable to commence and at least partially discontinue the flow of air from the part receivers to the vacuum source. When the air flow from the part receivers to the vacuum source is commenced, the component parts are temporarily attached to their respective part receivers by vacuum attachment. When the flow of air from the part receivers to the vacuum source is at least partially discontinued, the component parts are released from their respective part receivers. Advantageously, the component part carrier may be mounted by movement, such as translational movement, relative to a base member such as a track or rail, so that the carrier&#39;s movement during installation of the component parts is consonant with the movement of the platform along, e.g., an assembly line.  
           [0012]    In another aspect of the present invention, a method of simultaneously installing a plurality of component parts into a moving platform is provided. The method comprises the steps of: providing a plurality of component parts; providing a component part carrier having a plurality of part receivers positioned in a substantially fixed spatial relationship to each other; contacting the plurality of part receivers with the plurality of component parts; actuating a vacuum source fluidically connected to the part receivers thereby commencing the flow of air from the part receivers to a vacuum source and temporarily attaching the component parts to the part receivers by a vacuum attachment; translating the component part carrier to position the component parts in registry with a corresponding part reception site in a platform; and, at least partially terminating the flow of air from the part receivers to the vacuum source thereby releasing the component parts from the part receivers. A preferred method includes translating the component part carrier cooperatively with the moving platform so that installation of the parts may continue without the necessity of slowing or stopping the movement of the platform along an assembly line. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    [0013]FIG. 1 is a perspective view of a component part installer according to an embodiment of the present invention;  
         [0014]    [0014]FIG. 2 is a side view of a component part installer in relation to an assembly line worker and a vehicle body on an assembly line;  
         [0015]    [0015]FIG. 3 is a plan view of a component part installer and a vehicle body in an initial location on an assembly line, showing the component part installer in retracted position away from the vehicle body;  
         [0016]    [0016]FIG. 4 is a plan view similar to FIG. 3 of a component part installer and a vehicle body translating along the assembly line to a second location, showing the component part installer adjacent to the vehicle body;  
         [0017]    [0017]FIG. 5 is a plan view similar to FIG. 3 of a component part installer and vehicle body translating along the assembly line to a third location, showing the component part installer partially extending into the vehicle body;  
         [0018]    [0018]FIG. 6 is a perspective view of a component part, according to an embodiment of the present invention;  
         [0019]    [0019]FIG. 7 is an end view of a component part, according to an embodiment of the present invention;  
         [0020]    [0020]FIG. 8 is a side view of a component part, according to an embodiment of the present invention;  
         [0021]    [0021]FIG. 9 is a plan view of a component part, according to an embodiment of the present invention; and  
         [0022]    [0022]FIG. 10 is a vertical cross-sectional view taken along line  10 - 10  of the component part depicted in FIG. 9. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]    As shown in FIG. 1, in one embodiment of the present invention, a component part installer  20  is provided. Component part installer  20  comprises a component part carrier  22  shiftably coupled to a supporting surface  24  via a carriage  26  and an arm assembly  28 .  
         [0024]    Referring now to FIGS. 1 and 2, supporting surface  24  can be any stable horizontal, vertical or angled surface capable of rigidly supporting the weight and torque imparted by component part carrier  22 , carriage  26  and arm assembly  28 . Preferably, supporting surface  12  is a substantially horizontal overhead surface. Supporting surface  24  can include overhead horizontally extending rails  30 . Rails  30  preferably extend in a substantially horizontal direction corresponding to the direction of travel of an assembly line. As best seen in FIG. 2, rails  30  are substantially parallel to an assembly line track  32  which supports a vehicle body  34  via a suspension device  36 . Rails  30  are horizontally spaced from the track  32  and the vehicle body  34  so that component part carrier  22  can translate along the rails  30  and the arm assembly  28  can translate in and out of an opening, typically a door opening, in vehicle body  34 .  
         [0025]    As best seen in FIG. 1, carriage  26  is shiftably coupled to rails  30  by any means known in the art for providing translation of carriage  26  along rails  30 . Preferably, carriage  26  comprises a plurality of rollers  38  for providing translation along rails  30 . Carriage  26  further comprises a base  40  for rigidly supporting arm assembly  28 .  
         [0026]    As best seen in FIG. 1, arm assembly  28  is physically interposed between carriage  26  and component part carrier  22 . Assembly arm  28  provides translation of component part carrier  22  relative to carriage  26 . Arm assembly  28  also provides support for component part carrier  22  so that the downward force exerted on arm assembly  28 , due to the weight of component part carrier  22 , is at least partially counteracted by the upward bias of arm assembly  28 .  
         [0027]    Arm assembly  28  comprises a first member  42  having a pivot end  44  and a swing end  46 . Pivot end  44  is pivotably coupled to base  40  so that swing end  46  can rotate about pivot end  44 . First member  42  preferably projects in a substantially horizontal direction so that swing end  46  can be rotated substantially horizontally about pivot end  44 . In addition, swing end  46  is preferably capable of vertical translation relative to pivot end  44 . Such vertical translation of swing end  46  can be provided by any means known in the art. For example, vertical translation of swing end  46  can be provided by a four-bar linkage assembly  48 . First member  42  can include a hinge  50  located between pivot end  44  and swing end  46 . Hinge  50  provides a substantially vertical pivot axis in first member  44  and allows swing end  46  to be rotated substantially horizontally relative to hinge  50 .  
         [0028]    Arm assembly  28  further comprises a second member  52  having a first end  54  and a second end  56 . First end  54  is rotatably coupled to swing end  46  so that second member  52  can rotate around its longitudinal axis. Second member  52  is preferably maintained in a substantially upright position with first end  54  being spaced vertically higher than second end  56 . Four-bar linkage assembly  48  is preferably configured so that when swing end  46  translates vertically, second member  52  remains in a substantially upright position. In an alternative embodiment, not shown, second member  52  can comprise a four-bar linkage assembly for providing substantially horizontal translation of second end  56  relative to first end  54 .  
         [0029]    Arm assembly  28  further comprises a third member  58  having a proximal end  60  and a distal end  62 . Proximal end  60  is fixedly attached to second end  56 . Distal end  62  is fixedly attached to component part carrier  22 . Third member  58  is preferably maintained in a substantially horizontal position during translation of component part carrier  22 . Third member  58  is preferably spaced vertically lower than first member  42 .  
         [0030]    A translation force can be applied to arm assembly  28  by any means known in the art for providing horizontal and vertical movement of a mechanical arm. As shown in FIG. 2, the translation force can be provided manually by an operator  64  to provide selective placement of the arm assembly relative to the part receiving platform. Alternatively, the translation force can be provided by suitable automatically controllable mechanical devices known in the art. Further, the path of translation of arm assembly  28  can be controlled manually by operator  64 , as shown in FIG. 2, or by any suitable programmable automated device known in the art. Preferably, the translation force and translation path are provided by operator  64  who can inspect the vehicle body during part placement for quality assurance.  
         [0031]    Referring back to FIG. 1, component part carrier  22  is preferably a rigid frame capable of supporting a plurality of component parts  66  in a substantially fixed spatial relationship. Component part carrier  22  comprises an upper main member  68 , a plurality of legs  70  and a plurality of part receivers  72 . Each leg  70  has a proximal end fixedly attached to upper main member  68 , and a distal end fixedly attached to a respective part receiver  72 . Preferably, component part carrier  22  has four or more part receivers  72 , most preferably eight part receivers  72 . Each part receiver  72  is adapted for selectively holding and releasing a respective component part  66 . Each part receiver  72  preferably has at least one contact surface adapted to form a substantially flush fit with a portion of the surface of a respective component part  66 . Most preferably, each part receiver has at least two contact surfaces adapted to fit in registry with a surface of a respective component part  66 .  
         [0032]    The contact surface of each part receiver is fluidically connected with a vacuum source circuit. The vacuum source circuit comprises a vacuum source  74  and a switch  76 . Switch  76  is selectively actuatable to commence and at least partially terminate the flow of air from part receivers  72  to vacuum source  74 , such as by permitting the flow of air into the vacuum source  74  directly at the switch  76  or at another location along the circuit. When switch  76  is actuated to commence the flow of air from part receivers  72  to vacuum source  74  and the contact surfaces of part receivers  72  are simultaneously contacted with respective component parts  66 , component parts  66  are temporarily attached to part receivers  72  by vacuum attachment. When switch  76  is actuated to at least partially discontinue the flow of air from part receivers  72  to vacuum source  74 , component parts  66  are released from part receivers  72 .  
         [0033]    Vacuum source  74  can be any conventional air displacement device capable of creating a sufficient vacuum attachment force so that component parts  66  can be temporarily attached to part receivers  72  by vacuum attachment. As shown in the drawings, the vacuum source  74  is a vacuum pump coupled for movement with the carriage  26 , but alternatively the vacuum pump may be remotely located and connected by a length of flexible pneumatic tubing of sufficient length to connect to the carriage  26  and permit the carriage  26  to move along the rails  30 .  
         [0034]    Switch  76  is preferably manually actuatable by the operator and is fluidly interposed between vacuum source  74  and part receivers  72 . Switch  76  may be any conventional electrical or pneumatic control device that is selectively actuatable to at least partially discontinue the flow of air from part receivers  72  to vacuum source  74 . Preferably, switch  76  is a pneumatic switch.  
         [0035]    Switch  76  is preferably mounted on a manifold  78 . Manifold  78  is fixedly attached to second member  52 . Manifold  78  is fluidly interposed between vacuum source  74  and part receivers  72 . Manifold  78  is fluidically coupled to vacuum source  74  via at least one trunk line  80 . Manifold  78  is fluidically coupled to part receivers  72  via a plurality of feeder lines  82 . Manifold  78  is adapted to distribute the negative pressure created in trunk lines  80  by vacuum source  74  substantially evenly among feeder lines  82  so that each part receiver  72  exerts a substantially equal vacuum attachment force on each respective component part  66 .  
         [0036]    A handle  84  is preferably mounted on manifold  78  in close proximity to switch  76 . Handle  84  facilitates manual translation of component part carrier  22 . Further, handle  84  is positioned so that switch  76  can be actuated by human hands without releasing handle  84 .  
         [0037]    Component part installer  20  can further comprise a counter-force device  86 . Counter-force device  86  provides a stabilizing, lifting force which acts on the arm assembly  28  to which it is connected. Preferably, the upward bias of arm assembly  28  at least partially counteracts the downward force exerted on arm assembly  28  by the weight of arm assembly  28 , component part carrier  22 , and component parts  66 . Counter-force device  86  is preferably mounted on first member  42  so that an upward bias is provided to swing end  46  relative to pivot end  44 . Counter-force device  86  can be coupled to a portion of first member  42  which extends vertically above four-bar linkage assembly  48 . In this configuration, counter-force device  86  provides an upward bias to swing end  46  by pulling upward on the top member of four-bar linkage assembly  48 . As best seen in FIG. 2, counter-force device  64  preferably provides sufficient upward bias on first member  42  such that an operator  64  can repeatedly facilitate the translation of component part carrier  22  in both horizontal and vertical directions without exerting a human-fatiguing translation force. The counter-force device  64  may be a simple spring or other device well known to those skilled in the art.  
         [0038]    In an alternative embodiment, not shown, counter-force device  86  can be interposed at an angle between the upper and lower substantially horizontal members of four-bar linkage  48 . In such an alternative embodiment, counter-force device  86  is preferably placed at an angle such that the end of counter-force device  86  connected to the upper substantially horizontal member of four-bar linkage assembly  48  is positioned closer to swing end  46  than the end of counter-force device  86  connected to the lower substantially horizontally projecting member of four-bar linkage assembly  48 .  
         [0039]    FIGS.  2 - 5 , shown in a preferred embodiment of the present invention of, the installation of a plurality of component parts  66  in a platform  88 . As best seen in FIGS.  3 - 5 , platform  88  may be the floor of vehicle body  34  having a plurality of part reception sites  90 . Part reception sites  90  have a fixed spatial relationship to each other. Part reception sites  90  illustrated herein are cavities in the floor pan of vehicle body  34  where seat anchoring devices extend upward from under the floor pan. The spatial relationship of part reception sites  70  is substantially the same as the spatial relationship of part receivers  72 .  
         [0040]    By way of an example of one type of part which may be installed in accordance with the present invention, FIGS.  6 - 10  show component part  66  as a one-piece thermally expandable, flexible sealing member which is configured to correspond to the overall shape and size of part reception sites  90 . Of course, the part receivers  72  may be configured to hold and install other parts, the flexible sealing member illustrated being only one example thereof. In more detail, the illustrated component part  66  comprises a substantially rectangular lip  92 , sidewalls  94   a,b , end walls  96   a,b , bottom portions  98   a,b,  and an opening  100 . Sidewalls  94   a,b  and endwalls  96   a,b  extend downwardly from an inner periphery  102  of lip  92  to bottom portions  98   a,b . Opening  100  separates bottom portions  98   a,b . Bottom portions  98   a,b  comprise upper surfaces  104   a,b  which are substantially flat along a plane which is substantially parallel to that of lip  92 . Component part  66  is preferably formed of a thermoplastic material. More preferably, component part  66  is formed of a polymeric base which includes ethylene vinyl acetate (EVA) and an elastomer.  
         [0041]    Referring back to FIGS.  1 - 5 , to simultaneously install multiple component parts  66  in reception sites  90 , component part carrier  10  must first be loaded with component parts  66 . While component part carrier  22  is retracted from vehicle body  34 , as shown in FIG. 3, upper surfaces  104   a,b  of component part  66 , shown in FIG. 6, are contacted with contact surfaces of part receivers  72 . The flow of air from the part receivers  72  to the vacuum source  74  temporarily attaches component parts  66  to part receivers  72  by vacuum attachment.  
         [0042]    While component parts  66  are attached to part receivers  72  by a vacuum attachment, operator  64 , shown in FIG. 2, translates the carriage  26  along its rails  30  to follow the movement of the vehicle body  34  along its track  32  and shifts the component part carrier  22  from a retracted position, shown in FIG. 3, to a position adjacent to an opening in vehicle body  34 , shown in FIG. 4. As best shown in FIGS. 2 and 5, operator  64  translates component part carrier  22  through the opening in vehicle body  34  and into the interior of vehicle body  34 . The component part carrier is positioned so that component parts  66  are substantially aligned with part reception sites  90 . Component part carrier  22  is then lowered so that component parts  66  are in registry with corresponding part reception sites  90 . Advantageously, the carrier  22  remains substantially horizontal during the installation process whereby the component parts  66  are retained on their respective part receivers  72  and remain oriented in position for installation.  
         [0043]    While component parts  66  are in registry with part reception sites  90 , switch  76 , shown in FIG. 1, can be actuated to at least partially discontinue the flow of air from part receivers  72  to vacuum source  74 , thereby releasing component parts  66  from part receivers  72 . Before part receivers  72  are removed from component parts  66 , component part carrier  22  can be shifted downward to force component parts  66  further into part reception sites  90 , thereby forming a snug fit between component parts  66  and part reception sites  90  so that component parts  66  maintain registry with part reception sites  90  during movement of platform  88 . The component part carrier can then be shifted to remove part receivers  72  from component parts  66 , thereby leaving component parts  66  disposed within part reception sites  90 . Component part carrier  22  can then be removed from the interior of vehicle body  34  to a retracted position for loading a new set of component parts  66 .  
         [0044]    As shown in FIG. 2, during the above-described installation process, vehicle body  34  can be traveling along an assembly line via assembly line track  32  and suspension device  36 . Carriage  26  can be translated in a direction corresponding to the direction of travel of vehicle body  34  along the assembly line, thereby allowing multiple component parts to be simultaneously installed in platform  88  while platform  88  is in continuous motion.  
         [0045]    From the foregoing, it will be seen that this invention is well adapted to attain the objects herein above set forth, together with other advantages which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.  
         [0046]    Since many possible embodiments may be made of the invention without departing from the scope hereto, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrated and not in a limiting sense.