Patent Publication Number: US-11021200-B2

Title: Modular vehicle assembly system and method

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This divisional application claims priority benefit to U.S. Utility patent application Ser. No. 14/968,126 filed Dec. 14, 2015 which claims priority benefit to U.S. Provisional Patent Application No. 62/091,687 filed Dec. 15, 2014 the entire contents of both applications are incorporated herein by reference. 
    
    
     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&#39;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&#39;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&#39;s typically awarding portions of the assembly line Time A and Time B equipment to many different suppliers to leverage the respective supplier&#39;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&#39;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&#39;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 application equipment can simply be connected to coordinating equipment at a system integrator&#39;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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein: 
         FIG. 1  is a schematic of an example of a prior art vehicle assembly plant layout and assembly lines; 
         FIG. 2  is a perspective view schematic of one example of a prior art vehicle assembly station having a pallet-style vehicle conveyor; 
         FIG. 3A  is a perspective view schematic of an example of a modular vehicle assembly station of the present invention with an exemplary overhead-style conveyor and peripheral support device being installed; 
         FIG. 3B  is an alternate perspective view schematic of the example shown in  FIG. 3A  with several modular pallet devices installed on both sides of the assembly station; 
         FIGS. 4A-D  are alternate examples of configurations for one example of the modular application equipment pallet devices; 
         FIG. 5  is a perspective view schematic of an example of the modular application equipment pallet device and exemplary application equipment devices mounted thereon; 
         FIG. 6  is an enlarged perspective view schematic of the area marked “A” in  FIG. 5 ; 
         FIG. 7  is a schematic end view of an example of a modular vehicle assembly system station; 
         FIG. 8  is an alternate and enlarged portion of  FIG. 7  showing connection of an exemplary application equipment pallet device; 
         FIG. 9  is a schematic end view of an alternate example of a modular application equipment pallet device mounted atop of an exemplary frame structure; 
         FIG. 10  is a perspective view schematic of an example of a modular application equipment platform with a robot connected to a pallet-type conveyor; 
         FIG. 11  is a plan view schematic of a modular assembly system station including six modular pallet devices and four modular robot platform devices; 
         FIG. 12  is a perspective view schematic of an example of an assembly station protective fence and fence retraction device; 
         FIG. 13  is a right side view of the retractable protective fence in  FIG. 12 ; 
         FIG. 14  is a flow chart of an example of a method for assembling and installing modular application equipment pallets and associated application equipment; 
         FIG. 15  is a flow chart of an example of a method for assembling or installing a modular vehicle assembly system of the present invention; and 
         FIG. 16  is a flow chart of an example of a method for purchasing or sourcing vehicle assembly lines using non-model specific and model-specific equipment. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     Examples of a modular vehicle assembly system and methods  10  are described below and illustrated in  FIGS. 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 to  FIG. 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 floor  14 . In the example, a material entry area  20 , a material loading and sequencing or staging area  30 , and a plurality of assembly lines  38  (six shown in  FIG. 1  and identified as  40 - 45  as illustrated). Each assembly line  38  includes a vehicle-in-process travel path  60  running down each line  40 - 45 . 
     In the examples shown, two types of vehicle conveyors are particularly, but not exclusively, useful for transporting the partially completed vehicle body along path  60  and through assembly stations or cells  56 . As generally shown in  FIG. 2 , a pallet  106  generally supports a partially completed vehicle body (not shown). The pallet  106  is selectively moved along path  60  on a rail frame  110  having powered rollers to selectively move pallet  106  from assembly cell to assembly cell. An example of a powered pallet system is Comau LLC&#39;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 in  FIGS. 3A and 3B , a useful overhead conveyor is Comau LLC&#39;s VersaRoll® brand conveyor including powered rollers along an upper frame rail which engage and move a downward extending carriage along path  60  through the assembly cells  56 . 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 pallets  106  or overhead carriers  90  at desired positions in the assembly cells is Comau LLC&#39;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-style  106  ( FIG. 2 ) or overhead-style  90  ( FIGS. 3A  and B) vehicle conveyor or carrier, one or more exemplary assembly lines  40 - 45  may include a lower assembly path  60  and an upper return path  84  as 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 cells  56  by programmable industrial, multi-axis robots  150  described further below. The upper return path of travel  84  may 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 path  84  and 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 travel  60  to the upper path of travel  84 . 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 line  40 - 45  to raise a partially completed vehicle to the upper path  84 . Further, an elevated transverse conveyor (not shown) may move a partially completed vehicle body from an upper path  84  of one line  40 - 45  to an adjacent line for further build or assembly processes. 
     As best seen in  FIGS. 3A  and B, where an overhead conveyor  90  is used, a transverse tooling shuttle or conveyor device  112  may be used. The conveyor  112  allows for different tooling to accommodate different vehicle types to selectively move in and out of the assembly cell  56  along a path  116  that is substantially transverse to assembly path  60 . 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 to  FIGS. 3A  and B, an example of a modular vehicle assembly system  10  is illustrated. In the example, the system includes a pair of scaffold-like frames  120 . In the example, frame  120  includes a lower frame module  124  on each side of the assembly line path of travel  60  as generally shown (one assembly line described hereafter for convenience). In a preferred example, the lower frame module  124  is manufactured and assembled to close dimensional tolerances and rigidly and removable secured to the plant floor  14  through threaded studs connected to mounting plates secured to the floor  14 , typically concrete. In a preferred example, the lower frame modules  124  are precisely spaced laterally from a predetermined and known centerline of the assembly line  60  in the assembly facility. The longitudinal position of the lower frame  124  along 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 point  260  for the assembly station is determined as best seen in  FIG. 12 . In a preferred example, the predetermined reference point  260  provides an accurate and known location in the X, Y and Z dimensional coordinates from which other modular assembly system equipment for example the frames  120  are located from to support precision assembly operations along the assembly line. 
     In a preferred example, the lower frames  124  include an entrance point, for example the leading frame portion upstream, and an exit point, for example the trailing or furthest portion of frame  120  downstream. The lower frames  124  are precisely positioned longitudinally along path  60  from the known center or reference point  260  to provide a structurally rigid and dimensionally precise foundation for locating upper frames  130 . The precision mounting location of the lower frames  124  along path  60  and precision mounting locations for the robots  150  connected to the frame  120  relative to the known reference point  260  of the assembly cell  56  provide accurate, precise and predictable orientation of the robots  150  for programming the movements of the robots  150  assigned functions in the assembly cell  56 . In a preferred example, the lower frames  124  are non-model specific. That is, lower frames  124  are standard or generic and do not depend on which type of vehicle or vehicle body (or other product) will be built. The exemplary lower frames  124  are 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 in  FIGS. 3A , B,  5 ,  67 , an exemplary pair of upper frames  130  is illustrated. Each upper frame  130  is preferably precisely fabricated to small or close tolerances and mounted atop a respective lower frame  124  as generally shown (one described hereafter for convenience). Upper frame  130  includes vertical legs and an elevated floor  136  longitudinally extending along and parallel to path  60  forming a rigid scaffold-like assembly frame. Floor  136  is of a width  140  which is preferably about 60 inches. Other widths  140  and dimensions of upper frame  124  suitable 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 robots  150  attach to the underside of floor  136  and extend down below floor  136  as generally shown. The upper frame  130  precision mounting surfaces accurately and precisely position the robots  150  relative to the upper  130  and lower  124  frames and assembly cell center point  260  providing a high level of dimensional and locational predictability and repeatability in the initial installed position and orientation of robots  150  with respect to the assembly cell for programing and operation. Alternately, precision located mounting holes are provided in the upper frames  130  to accept modular robot mounting plates (not shown). The mounting plates, for example, can be connected to the robots at the integrator&#39;s (i.e. vendor/supplier) facility with easy and precise connection to the upper frames  130  when installed in the assembly plant. 
     In a preferred example not shown, tapered locating pins may be installed on the upper portions of the lower frame  124  and coordinate with apertures or other details in the mating upper frame  130 . The tapered locating pins may be used to guide and position the upper frame  130  into 3-dimensional X, Y and Z precision location relative to the lower frame  124  and then secured in place with large bolts, other fasteners or other securing methods known by those skilled in the art. 
     Lower  124  and upper  130  frames are preferably made from welded steel elements although other materials known by those skilled in the art may be used. It is understood that lower  124  and upper  130  frames 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 in  FIGS. 2 and 3A , B, the power and controls for each robot  150  are preferably housed in control cabinets  160  secured to upper frame floor  136  as generally shown. Other positions of the cabinets  160  suitable for the application and number of robots  150  (or other assembly tools and equipment) for a particular assembly cell  56  known by those skilled in the art may be used. 
     Referring to  FIGS. 4-8 , an example of a modular application equipment (AE) pallet or support  170  is illustrated (three (3) shown in  FIG. 5 ). As best seen in  FIG. 5 , in the example, AE pallet  170  includes a mounting surface or top  174  having a width  176  and vertical joists or supports  180  (three shown per pallet) as generally shown. AE pallets  170  may include a bottom  182  forming a rectangular pallet-like structure. AE pallet may further include a back panel (not shown) and a front panel (not shown). Although mounting surface  174  is 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 pallet  170 , mounting surface  174  is a rigid panel having a plurality of through holes or slots, mounting bosses, weld nuts and/or other features for mounting application equipment (AE)  190  suitable for the assembly operations in the assembly cell  56  and most preferably for a particular assembly tool, for example a robot  150 . For example, mounting surface  174  can be a rigid steel plate with holes positioned in a 100 millimeter grid pattern for ease of positioning and securing all types of AE devices  190 . In a preferred example, where three (3) inverted robots  150  are connected to upper frame  130 , three (3) AE pallets  170  are preferably used providing the respective AE device  190  needed to support the respective robot  150  assigned an assembly task. As seen in  FIG. 5 , three (3) different forms of AE devices  190  are illustrated. In the middle AE pallet  170 , a fluid storage and dispensing system  194  is secured to top  174  as 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 device  170  has a consumable materials fastener feeder  198  connected 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 support  170  includes a third application equipment, for example a welding controller for a resistance spot welding of aluminum application. Other AE devices  190  needed 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 devices  190 , and consumable materials used thereby, known by those skilled in the art may be packaged and secured to a respective AE pallet  170 . Although described as useful with robots  150 , it is understood that AE devices  190  can 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 to  FIGS. 5 and 6 , one example of an AE pallet connector  186  is illustrated. In the example, AE pallet  170  includes hooks  188  rigidly mounted to two or more vertical supports  180  as best seen in  FIG. 6 . Exemplary hooks  188  laterally extend outward from vertical supports  180  and engage cooperating structures, for example slots  144  in a laterally outward facing surface  142  of upper frame  130  forming a localized lateral continuation of floor  136  as best seen in  FIG. 7 . Alternately, the coordinating mounting holes may be in the floor  136 . 
     Referring to  FIG. 9 , an alternate example of mounting AE pallet  170  to upper frame  130  is shown. In the example, AE pallet  170  is mounted atop upper frame floor  136  through mechanical fasteners as generally shown (space shown between  170  and  136  for ease of illustration). In this configuration, the width  140  of upper frame  130  may be increased (not shown) to accommodate the width  176  of AE pallet  170  while allowing adequate space for walkway  210  as described below. Other structures, orientations and fastening methods for removably mounting AE pallets  170  to upper frame  130  known by those skilled in the art may be used. 
     In the examples, AE pallet  170  is configured to form a pallet-like support structure for any AE device  190  to provide consumable materials, other materials, or services (for example electrical power, fluids or data) to the assembly line, preferably adjacent exemplary industrial robots  150 . In a preferred example, pallet  170  width  176  is approximately 36 inches. In a preferred example, the combined widths  140  of upper frame  130  floor  136  and width  176  of AE support are less than 96 inches which is the standard width of a commercial boxcar shipping container. Other widths  140  of floor  136  and AE pallet  170  may 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 pallet  170  is 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 pallets  170  are shipped “empty” to a supplier/vendor responsible for providing AE devices  190  to support assembly operations in one or more assembly cells  56  along one or more assembly lines  38 - 45 . The vendor can design and package the AE devices  190  in the space provided by the modular pallet  170 , securely mount the AE device  190  to the top  174  and fully test and commission the operation of the equipment at the supplier&#39;s facility thereby providing tested and ready to use equipment on installation at the assembly plant. It is understood that AE devices  190  may be mounted in other orientations with respect to pallet  170 , for example connected to the underside of top surface and extending downward. Other mounting and orientations of AE devices  190  to pallets  170  known by those skilled in the art may be used. 
     As best seen in  FIGS. 4A-D , the modular design of AE pallets  170  provides for several configurations depending on the assembly operations for a particular assembly station  56 . As best seen in  FIGS. 3A and 4A -D, where an AE pallet  170  and AE device  190  is desired to be installed to upper frame  130 , a safety rail  146 , normally installed to upper frame surface  142  or floor  136 , is simply disconnected from upper frame floor  136  and mounted to rail connection points (not shown) on AE pallet  170  as generally shown. Securing AE pallets  170  and reconfiguring the AE devices  190  for assembly cell  56  can be done in a matter of minutes versus hours or days with conventional assembly systems. 
     Referring to  FIGS. 5, 7 and 8 , an example of a conduit  200  is shown. Conduit  200  includes one or more of cables, wiring harnesses and/or pipes,  202 ,  204  and  205  positioned between the AE devices  190  and the assembly cell are shown. In the example, conduit  200  may be a single or multiple conduits/cables/pipes  202 ,  204  and  205 , used to route, for example, an electrical and/or data cables  202  for the transfer of electrical power and information data from the control cabinets  160  to supply the necessary electricity and data to the AE devices  190  to, for example, power a fluid distribution pump  194  to supply pressurized adhesive or sealer to robot  150  or other assembly tools or cell equipment. As best seen in  FIG. 8 , conduit  200  may include a cable  204  connected between the AE device  190  and the assembly tool exemplary robot  150  to 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 equipment  190  in the assembly cell. 
     In a preferred example, where a robot  150  uses consumable materials, for example rivets, screws, or weld studs, to perform the predetermined assembly task, conduit  200  may include a pipe  205  is connected to the AE device  190  and routed through or around the AE pallet  170 , under upper frame  130 , through or around robot wrist  152  to the end effector  156  for 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 cell  56 . Where a robot  150  is tasked with welding operations, the fluid dispensing system  194  may 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 conduit  200  to support the welding operation. It is understood that conduit  200  could 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 pallet  170  includes fastener AE devices  190 , conduit  200  may include hoses or pipes for the transport of fasteners into the assembly cell. In a preferred example, AE pallet  170  includes one or larger routing apertures (not shown) in top  174  and open face  178  for the ease of routing conduit  200  laterally toward upper frame  130 . The assigned robot  150  or other assembly cell tools would include the appropriate coordinating and reciprocal connectors so conduits  200  and/or  202 ,  204  and  205  can be rapidly connected for communication of consumable materials, data and other items on installation of the modular AE pallet  170  to upper frame  130  as described. Other communication lines, conduits and routing techniques and connections known by those skilled in the art may be used. For example, the conduit  200  may simply be routed around the AE pallet floor versus through apertures in the floor as described. 
     It is understood that conduit  200  may 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 device  190  may have a short conduit or simply connectors on the AE device  190  so it can be rapidly connected and placed in communication with the assembly cell control cabinet and/or the assembly tool in the manners described. I combination of conduits  200  is 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 pallet  170  comes “pre-wired” and includes coordinating connectors on the pallet  170 . For example, the pallet  170  may have common connectors or a bank of plugs wherein the AE device plugs into the pallet  170 . 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 device  190  in 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 device  190  fails and it is too time consuming or costly to repair or replace the first AE device  190  on site at the assembly line, the entire first pallet  170  can be disconnected and replaced with a replacement first modular pallet  170  with a pre-installed and tested replacement first AE device  190  with 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 equipment  190 . 
     The modularity also is a major advantage for vehicle model and other product changeovers requiring reassignment of a robot  150  assembly operation or other assembly line tools/equipment. For example, a second AE pallet  170  with a second AE device  190  suitable for the new assembly tool or operation can be quickly mounted to upper frame  130  through a forklift or existing gantry crane and connected to the retasked or new assembly tool through conduit  200  as described above. In a preferred example, the second AE pallet would be the same modular AE pallet  170  used with the first AE device, but having a different, second AE device  190  connected 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 pallet  170  may be used to accommodate the various AE devices  190  or assembly line operations. 
     The elevation of the application equipment  190  further removes such equipment from traditional placement on plant floor  14  and routing of the communication or support lines up to the inverted robots  150  which typically required dedicated frames to support and route the lines, for example hoses and fastener conduits. 
     In a preferred system  10  and application of AE pallets  170  and application equipment  190  shown in  FIGS. 7, 8 and 9 , the dimensional size of floor  136  and the placement of control cabinets  160  and application equipment  190  preferably provides for a walkway  210  along floor  136  longitudinally along upper frame  130 . In one example, this is advantageous for access and maintenance of systems in the control cabinets  160  and AE devices  190  positioned thereon or connected thereto. Further, as the AE device  190  which provides consumable items such as adhesives and fasteners to the assembly cell, these consumable materials need to periodically be replenished. Walkway  210  provides a pathway for operators (see  FIG. 8 ) to maneuver and restock these consumables for continuous assembly station operation. As an example shown in  FIGS. 7 and 8 , a drum of fluid can be raised by a forklift and installed atop floor  136 . A dolly or cart can be used by an operator to move and replace an empty fluid storage container for a fluid dispenser  194 . 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 robot  150  by the application equipment  190  and conduit  200  as described. 
     Referring to  FIG. 4B , an example of a distribution deck  212  is shown. Distribution deck  212  is 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 devices  190  mounted on AE supports  170 . In the example shown, deck  212  is positioned at one or both ends of an assembly line  40 - 45  ( FIG. 1 ) and has a platform which is preferably directly adjacent and at the same elevation as floor  136  of the upper frame  130  and in the exemplary AE pallet floor  174  shown in  FIGS. 4, 7 and 8 . In the example deck  212 , consumables, for example 55 gallon drums of sealant  216  for use in fluid distribution device  194 , would be raised up to platform  214  by 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 deck  212  along path  210  to the appropriate AE pallet  170  where the consumables are needed. This is very advantageous for continuous operation of the AE devices  190  and assembly station  56 . The position of the AE devices  190 , consumables  216  and workers above the assembly cell  56  for this work is very advantageous for plant logistics, efficiency and safety. Other methods of depositing the consumables  216  on platform  214  and movement along path  210  may be used as known by those skilled in the art. 
     Referring to  FIG. 1 , in a most preferred example, a distribution deck  212  would be provided at one end of each assembly line  40 - 45  adjacent to the material load and sequence area  30 . In one example, distribution deck  212  may be continuous and span several or all assembly lines  40 - 45  or be individual to each line where consumables are needed to support assembly operations. The consumables  216  would travel the least distance from the material entry area  20  to the assembly line and thus further simplify assembly plant floor congestion and logistics. Other configurations and locations of distribution deck  212  known by those skilled in the art may be used without departing from the present invention. It is further understood that distribution deck  212  may serve other purposes than receipt of consumable materials as known by those skilled in the art. 
     Referring to  FIGS. 10 and 11 , an example of an aspect of system  10  includes modular assembly tool (AT) platforms or trays  220  to provide assembly tools or other assembly equipment, for example programmable multi-axis robots  226 , additional AE devices  190  and associated accessories or devices used thereby. In one example of an AT platform  220 , modular robot platforms  220  are illustrated (two shown in  FIG. 10 , four shown in  FIG. 11 ) at floor level  14  of the assembly cell  56 . In the exemplary AT platforms  220 , a floor-positioned industrial multi-axis robot  226  having a principal axis of rotation  230  (shown in  FIG. 13 ) is mounted to a base  236 . In a preferred example, base  236  includes a base plate having precision, most preferably equally spaced, mounting points or holes  240  for mounting the robot  226 . The exemplary base plate is preferably mounted to frame rails  246  that extend laterally outward from assembly path  60  as generally shown. Rails  246  preferably also include precision positioned mounting points  250 , 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 rails  246 . 
     In a preferred application, rails  246  are rigidly connected to a continuous product conveyor or other equipment positioned along the assembly line or path  60  relative to the assembly station reference point  260  as best seen in  FIG. 11 . Connection of the modular AT platform  220  including exemplary frame rails  246  can be made through use of rigid brackets  254  mounted in holes  252  as generally shown or other connection devices and configurations known by those skilled in the art. In a preferred example, conveyor rail holes  252  are equally spaced apart and generated with close/small dimensional tolerances for accuracy and precision mounting of the AT platforms  220 . Mounting points  252  may include other structures to securely connect AT platform  220  to the conveyor or other assembly station structure for the particular application. 
     Although platform  220  base is shown including rails  246 , it is understood that the frame or support structure can vary depending on the assembly tools and AE equipment and application. For example, support  220  may include a pallet-like structure as  170  so the AT platform  220  can 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 rails  246  or other structures known by those skilled in the art. It is understood other platform  220  constructions to positon and mount platform  220  to the conveyor or support structure  110  can be used as known by those skilled in the art. 
     As discussed above for the inverted robots  150 , the exemplary precision base plates  236 , rails  246  and mounting holes  240 ,  250  and  252  provide for accurate, precise and repeatable X, Y and Z coordinate dimensional positioning of the robot  226  relative to the known assembly cell center point  260  and other assembly station equipment thereby facilitating rapid placement, plug and play and programming of the exemplary robots  226  for assembly operations once installed at the assembly plant. AT platform  220  may 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 frames  124  described above and below for  FIG. 15 . 
     Modular AT platforms  220  may further include the necessary control cabinets  156  to power and communicate programs and data with the respective assembly tools and AE devices  190  installed on support  220 . Similar to the modular AE pallets  170  and AE devices  190  discussed above, one or more of the assembly tools, AE devices  190  and control cabinets can be pre-installed on base plates  236  and/or frames/platforms  246  at the assembly tool or other supplier&#39;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 pallets  170 , the AT platforms  220  can be pre-wired and cabled as necessary with a conduit  200  for plug and play installation and operation at the assembly facility as similarly described above. The AE devices  190  can supply consumables and other materials and functions to the assembly tools, for example robots  226 , as described for AE pallets  170 . 
     The preferably self-contained, operational and initially tested/commissioned modular AT platforms  220  and 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 pallets  170  and AE devices  190 . 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 platform  220  can be mounted to the base  236  or 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 robots  226  are tasked with spot welding functions, an example of an AE device  190  can be automated weld tip dressers (not shown) precisely positioned on a larger base plate  236  or frame relative to the robot. For example, at scheduled intervals, the robots  226  can 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 devices  190  discussed 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 to  FIGS. 12 and 13 , another aspect of an example of system  10  includes a modular protective fence or guard  270  which assists in preventing personnel from entering assembly station  56  during operation. In the example, fence  270  includes a first frame  272  and a second frame  273  as generally shown. In a preferred example, each frame  273  and  273  includes a vertical post  274 , an upper support  276 , an upper rail  278  and a lower rail  280 . In the example fence  270 , one or more front panels  286  extending along parallel to assembly path  60  and side panels connected between the upper  278  and lower  280  rails are used. In a preferred example, each fence frame is rigidly mounted to and cantilevered from the assembly station lower  124  and upper  130  frames as generally shown. This advantageously places the lower rail  280  and side panels  290  a predetermined height  294  above the plant floor  14  negating traditional mounting structures to the plant floor  14 . 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. 
     Front  286  and side  290  side 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 fence  270 , the front panel  286  is slidingly mounted in guides  296  and connected to a retractor device  300 . An example of a retractor device  300  includes an electric motor  302  mounted to upper frame  130 , a cable  304  and a stationary pulley  308  as generally shown. The retractor is selectively operable by an operator or control system (not shown) to raise the front panel from a first lower position  310  proximate floor  14  to a raised upper position  316 . Upper position  316  is preferably of sufficient height such that operators and other equipment, for example forklifts, can enter assembly cell  56  and access and move assembly tools and other equipment to and from assembly cell  56  as necessary in the normal operation of the facility. 
     As best seen in  FIG. 12 , in an application of fence  270  with use of AT platforms  220 , the guides  296  are preferably positioned laterally outward from the assembly tool robots  226  and laterally inward from control cabinets  156  and AE devices  190  as generally shown. This provides access to the assembly tool controls and AE devices  190  to, for example replenish consumable materials provided to the assembly tools by the AE devices  190 . 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 fence  270 , the front panel  286  is normally positioned in the lower position  310  when the assembly station  56  is energized or in active assembly operations. When maintenance or access to equipment inside of assembly cell  56  is required, retractor device  300  can be engaged manually or through signals received from a local or central controller (not shown), to raise front panel  286  to the upper position  316  allowing personnel and equipment easy access into the cell  56  without the need for disassembly or partial removal/relocation of traditional protective fences or guards. It is understood that different configurations of fence  280  can be made to suit the particular assembly cell or line and known by those skilled in the art. Further, retractor  300  can 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 to  FIG. 14  a flow chart of an exemplary process  400  to build and install AE pallets  170  in an exemplary robot assembly tool application is shown. In the exemplary process, at step  410  it is determined the number and specific assembly operations that will be performed in one or more assembly stations  56 , for example exemplary vehicle body assembly operations executed by industrial robots  150  with various end effectors for a variety of assembly operations. A plurality of modular, and preferably identical, AE pallets  170  are fabricated having the structural and spatial features described in the examples above in step  420 . In step  430 , the modular AE pallets  170  are shipped “empty” in large quantities to a respective vendor for installation of an AE device (or devices)  190  by the vendor for a particular robot  150  or other assembly tools. 
     In an optional step  435 , the installed AE device  190  on the modular pallet  170  is pre-wired/pre-cabled with conduit  200  including power and data communication lines  206  appropriate for the assembly station, assembly tool and/or assembly operation and mated with coordinating connectors for attachment with connectors on the control cabinets, the robots  150 , other assembly tools or other assembly cell equipment. The AE device  190  is then preferably tested/commission at the vendor or system integration to ensure proper operation before shipment to the assembly plant. In some AE devices  190 , 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 step  440 , the modular AE pallet  170  and installed AE device  190  is shipped to an intermediary system integrator facility, or alternately directly to the assembly plant, and matched with the prefabricated assembly scaffold frame  120 , conveyors, non-model specific equipment, for example pre-installed robots  150 , and selected model-specific equipment assigned the assembly task supported by the application equipment  190 . The pallet  170  may be elevated into position proximate upper frame  130  and floor  136  by a forklift or other lifting mechanism. The modular pallet  170  is then engaged to the upper frame  130  in the examples described, for example engagement of hooks  188  with coordinating slots  144  in upper frame  130 . 
     In exemplary step  450 , the application equipment conduit  200  is routed and the prewired or pre-cabled lines  202 ,  204 ,  205  and/or  206  are connected to the pre-wired or pre-cabled robot  150 , control cabinets or other cell equipment for rapid install, communication and operation of the assembly cell  56 . In an optional step (not illustrated), consumables  216  are transferred to and placed on upper frame(s)  130  through distribution decks  212  to supply the respective AE devices  190  with needed materials to support the predetermined assembly operations. 
     In an optional step  460 , on a failure or required heavy maintenance of the AE device  190  installed on the modular AE pallet  170 , the entire pallet  170  is preferably disconnected from the control cabinet, robots and upper frame  130  and quickly replaced with another pallet  170  with replacement or alternate AE device(s)  190 . This equally applies where a product model changeover occurs and/or robot tasks changed. The existing AE pallets  170  with AE device  190  is disconnected and swapped out with an alternate pallet  170  having the appropriate AE device  190  for the new assembly task. 
     As described, the process  400  may equally be applied to AT platforms  220 , or the AE devices  190  used therewith as described. For example, if a robot assembly tool fails or needs heavy maintenance, the modular AT platform  220  can be disconnected and replaced with a new or alternate assembly tool and AE devices  190  as required, and connected to the conveyor or other equipment as described above. The mounting points of the base  236 , rails  246  and conveyor provide for rapid reconnection of a replacement AT platform  220  relative to the assembly station and/or assembly station reference point  260  thereby minimizing reprogramming or calibration of the new assembly tool. 
     Referring to  FIG. 15  an exemplary method  500  of assembling or installing a modular vehicle assembly system  10  is illustrated. In the example, prefabrication of system  10  infrastructure such as frames  120 , conveyors or transports  48 , assembly tools for example robots  150 / 226  and 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 line  60  is 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 point  260  may be determined as described above. 
     In the example, in step  510  lower frame  124  mounting plates are secured to the assembly plant floor  14  in predetermined locations relative to the assembly line  60 , assembly center line and/or assembly cell centerpoint  260  as generally described and illustrated. In step  520 , the lower frames  124  are removably secured to the mounting plates on both sides of the assembly line path  60 . 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 frames  124  are mounted to the floor at predetermined locations which then the below conveyor is positioned and mounted with respect thereto. The assembly cell reference point  260  may then be established based on the installed frame and conveyor. 
     In step  530  the vehicle conveyor system along assembly path  60  is installed as well as any framing needed where a return conveyor along a return upper path  84  is installed. In an optional step  535  where an overhead conveyor is used as generally shown in  FIG. 3B , a transverse tooling conveyor  112  may be installed. In a preferred example, the lower frames  124 , and conveyors  50 / 52 / 90 / 110  defining respective assembly paths  60 / 78  and  84 , tooling conveyor  112  (if an overhead conveyor system) and protective fences  280  are 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 step  540 , the assembly station upper frame  130  is installed and secured atop the lower frame  124 . In one example, the assembly tool industrial robots  150  and control cabinets  160  are pre-installed on the upper frame  130  as a unit by a vendor prior to delivery to the assembly cell and prior to securing it to lower frame  124 . In a preferred example, the upper frames  130 , 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 robots  150  and appropriate control cabinets  160 . The vendor, similar to that described for AE pallets  170  and AE devices  190 , installs and commissions the assembly tools and/or model specific equipment on upper frame  130  (or as much as practically possible depending on the equipment and application) at the vendor or system integrator&#39;s facility prior to shipment to the assembly facility for installation into the assembly station  56  and final commission for production assembly. Alternately, the robots  150  and control cabinets  160  may be installed following installation of the upper frame  130  onto the lower frame  124  in the assembly facility or in another sequence as known by those skilled in the art. 
     In exemplary step  550  the AE pallets  170  with preinstalled and commissioned vehicle/product model specific AE devices  190  are transported to the assembly facility and secured to upper frames  130 , coordinated with the appropriate control cabinet, and electronically connected to the robot  150 , 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 platforms  220  for a pallet-style conveyor system ( FIG. 2 ) as generally described above. 
     In exemplary step  560 , 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 step  570 , any remaining protective fences  270  to 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 fences  270  may be installed earlier as described or where appropriate in the cell assembly process. 
     Referring to  FIG. 16  another exemplary aspect of the invention is illustrated. In  FIG. 16  an exemplary process, business method or solution  600  for 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 system  10  described above, but may be used with other assembly operations for other products. It is understood the method  600  can be used for products other than vehicle body assembly as known by those skilled in the art. 
     In the example, step  610  establishes 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 step  620 , 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 step  620 , the assembly operations and equipment necessary for completing the assembly tasks are determined for each assembly line  40 - 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 system  10  is: 
     Vehicle Body Non-Model (NM) Specific: 
     Conveyor (overhead-style  90  or pallet-style  106 );
         Both along assembly path  60  and any return path  84 ;   Base conveyor pallets  106  or suspended carriages;   Component and subassembly delivery devices (in system  10  provided by carts  62  or carriage racks  94 );   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;       

     Lower  124  and upper  130  assembly cell frames (without robots  150  or control cabinets); 
     Frame  54  for return conveyor along path  84 ; 
     Carriage/pallet elevator device to move from lower path  60  to upper path  84 ; 
     Transverse tooling conveyor  112 ; 
     Robots  150 / 226  that are not preprogrammed for particular assembly operations; 
     Modular AE pallets  170  (without application equipment  190 ); 
     Distribution decks  212 ; 
     Modular AT platforms  220  (without robots or control cabinets or accessories); and 
     Partial or all protective fencing  270 . 
     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 conveyor  112 ; 
     Robots  150 / 226 , robot controls and control cabinets  160  and preprogrammed and stored software for particular assembly tasks/operations;
         Robot end effectors  156 ;   Any portion of conduit  200  including pre-plumbing, wiring, cables, pipes and connectors of robots/assembly tools to accept and connect to AE devices  190  and consumable materials;       

     AE devices  190 ; and
         Any portion of conduit  200  including pre-plumbing/wiring, cables, pipes and connectors on AE pallet  170  and AT platforms  220 .
 
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 step  630 , 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 system  10 , 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 system  10 , 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 step  635 , fabrication can begin on the system  10  modular non-model specific infrastructure and equipment. 
     In step  640 , 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 step  640 , supply contracts for the model specific equipment for each assembly line  40 - 45 , or combinations of assembly lines, may be awarded to other integrators/vendors. During this period  640 , the non-model specific equipment is already partially or wholly awarded and preferably fabrication already underway. 
     In a preferred example of step  640 , each winning model specific vendor would be responsible for the required product throughput performance for the awarded lines. It is understood that steps  635  and  640  can occur simultaneously or even switched depending on how long the lead times are for effective management of the quotation process. 
     In exemplary step  650 , the awarded model specific equipment is designed. During this period, fabrication of the awarded non-model specific in step  635  continues. Where appropriate, in step  655  installation 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 frames  130 , AE pallets  170  and AE platforms  220 , these can be shipped to the model specific vendors in step  660 . 
     In exemplary step  670 , the model specific equipment is fabricated and commissioned/tested. In a preferred example respecting upper frames  130 , AE pallets  170 , AE supports  220  and necessary AE devices  190  are installed, wired and plumbed with the appropriate cables and harnesses and tested at the vendor&#39;s facility as generally described above. 
     In exemplary step  680  the 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 pallets  170  with installed AE devices  190 , the AE pallets are lifted into positon and quickly secured to upper frame  130  as previously described. The conduit  200 , which may include one or more of  202 ,  204 ,  205  and  206  are quickly and readily connected to the control cabinets, robot  150  (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 platforms  220  as 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 frame  130  may have been shipped to the model-specific vendor. In such an instance, the robots  150 , AE pallets  170 , AE devices  190 , and control cabinets  160  may arrive to the assembly plant and be installed as a completed unit atop the lower frames  124 . Alternately, the separate AE pallets  170  shipped to the assembly facility, but can be installed after the upper frame and robots are installed on the lower frames  124 . 
     In one optional step (not shown), on initial installation or once production assembly begins, for example if a particular first AE device  190  fails or needs maintenance or refurbishment, the entire first AE pallet  170  or platform  220  that the respective failed first AE device  190  or assembly tool is secured to can be quickly disconnected and removed from upper frame  130  or conveyor and replaced. In one example, new (or refurbished) and tested replacement first AE device or alternate second AE device  190  preinstalled on an alternate or second AE pallet  170  can be raised, secured to upper frame  130  and 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 lines  40 - 45  throughput 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 methods  400 ,  500  and  600 , 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 pallets  170 , AT platforms  220  and fence  270  may all be included, or separately included in various combinations to suit the particular application, to form the system  10  structure and methods as described and/or illustrated herein. 
     While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.