Patent Description:
Referring to <FIG>, an example of a conventional pallet system <NUM> used to support a partially completed vehicle, for example a sheet metal body of a passenger vehicle (not shown) is illustrated. The pallets <NUM> supported the partial vehicle bodies and are transferred in sequential fashion by a conveyor (not shown) through numerous assembly stations (not shown), for example spot welding and brazing stations, along an assembly line.

In conventional pallets systems <NUM>, a pallet <NUM> typically included a pair of longitudinal rails <NUM> oriented along a longitudinal axis <NUM> (the X coordinate direction) and defining a first end <NUM> and a second end <NUM> of the pallet. Crossmembers <NUM> spanned laterally between the rails <NUM> along a lateral axis <NUM> (the Y coordinate direction) defining a rigid pallet structure.

In order to elevate and support the vehicle body, several support beams <NUM> would be positioned across the rails <NUM>, each support beam <NUM> including a pair of risers <NUM> extending vertically along a vertical axis <NUM> (the Z coordinate direction) as generally shown (four support beams and a total of eight risers <NUM> shown in <FIG> as an example). The number of support beams <NUM> and risers <NUM>, and position of the support beams <NUM> and risers <NUM> depend on the size, length and width of the vehicle body and automotive manufacturer specifications. Although each support beam <NUM> shows use of two risers <NUM> per support beam, it is understood that one riser <NUM>, or more than two risers <NUM> per support beam <NUM> may be used depending on the application.

As best seen in <FIG>, conventional pallet <NUM> support beams <NUM> included precision machined locating pads <NUM> for receipt and mounting of a riser <NUM> thereon. Risers <NUM> include a base <NUM> and several mounting bolts <NUM> (four shown) for securing each riser <NUM> to the support beam <NUM> preventing relative movement between the riser <NUM> and the support beam <NUM>. An additional locking bolt or dowel <NUM> (two shown) would be inserted into a predrilled hole through the base <NUM> and into the support beam <NUM> to lock the riser <NUM> in a predetermined position which was an improvement in positional accuracy and repeatability over prior designs. Each riser <NUM> would include a locating pin <NUM> (shown in <FIG>) which would be positioned to engage the vehicle body at predetermined positions on the vehicle body and securely hold the vehicle body in place throughout the various assembly processes.

In vehicle pallet systems, it is of critical importance that the locating pins <NUM> are positioned accurately and precisely in all three coordinate dimensions X, Y and Z so as to position the vehicle body in known dimensional positions relative to the pallet <NUM> and the various assembly stations so that precision equipment, for example programmable industrial robots, can carry out various operations on the vehicle body. Current industry dimensional tolerance standards require the locating pins <NUM> to be within <NUM> - <NUM> millimeters (mm) from a predetermined design position.

Conventional pallet systems <NUM> also included a hook and armature linkage inside the risers <NUM> and locating pins <NUM> along with actuators <NUM> positioned on the support beam <NUM>. On rotation of an actuator arm (not shown) at the actuator <NUM>, a linkage <NUM> positioned across the support beam <NUM> and inside the hollow riser <NUM> would manipulate a hook (not shown) positioned inside the hollow locating pin <NUM> to extend the hook, engage the vehicle body and lock the vehicle body to the riser preventing relative movement of the vehicle body from the risers until the actuator <NUM> is moved to retract and disengage the hook. An example of a suitable actuator <NUM> and hook system is described in <CIT> assigned to the present Applicant.

Early prior pallet systems <NUM> rigidly fixed, for example welded, each support beam <NUM> and onboard risers <NUM> to the rails <NUM> to prevent relative movement of the risers and locating pins <NUM> from their fixed positions. Due to the many different sizes, lengths and shapes of vehicle bodies, early prior pallet systems <NUM> could only be used for one vehicle due to the pallet <NUM>'s fixed position of the support beams <NUM>, risers <NUM> and locating pins <NUM>.

In more recent years, an improved pallet design allowed movement of one support beam <NUM> along the longitudinal axis <NUM> of rails <NUM>. This would allow a pallet <NUM> to move one set of risers to a different longitudinal axis <NUM> (X dimension) in order to accommodate a different vehicle body that had one set of holes in the sheet metal in a different longitudinal position so the pallet could accommodate the vehicle body different hole pattern. However, these improved pallets were only useful for another vehicle body if the same size/diameter riser locator pins <NUM> were used for both vehicles which also varies from vehicle body model to model. Thus, this improved pallet was also limited in its flexibility to accommodate different vehicle body models and changes in the model production sequence.

In modern vehicle assembly facilities, it is desirable and increasingly common to vary the type or model of vehicles that are assembled along an assembly line. The ability for a manufacturer to change the vehicle styles or bodies being manufactured is highly desirable to meet customer demand for popular vehicle types. In prior assembly facilities, on a vehicle model or style changeover, much of the assembly line equipment and fixtures, for example vehicle pallets <NUM>, would need to be changed to accommodate the new vehicle build. Due to the fixed geometry of prior pallets <NUM>, support beams <NUM>, and risers <NUM>, the entire pallets <NUM> would need to be removed from the production line and stored or racked until the vehicle production schedule returns to that vehicle style. Typical vehicle pallets <NUM> are each <NUM> meters (m)(<NUM> feet) long, <NUM> meters (m) (<NUM> feet (ft. ) wide, and weigh approximately <NUM> kilograms (kg)(<NUM> pounds (lb). Thus, movement of the pallets <NUM> from the assembly line and storage requires heavy equipment and substantial storage space at the assembly facility.

There is a need for an improved vehicle assembly pallet which provides flexibility to rapidly accommodate different vehicle body styles and which maintains the necessary accuracy and precision required of modern vehicle assembly systems.

A system for reconfiguring an assembly pallet for use in the assembly of vehicle bodies according to the present invention is defined in claim <NUM>. Further preferred embodiment of the present invention are defined in the dependent claims.

These and other aspects of the present invention are disclosed in the following detailed description of the embodiments, the appended claims and the accompanying figures. BRIEF DESCRIPTION OF THE DRAWINGS.

The invention is best understood from the following detailed description when read in conjunction with the accompanying drawings.

Referring to <FIG> and <FIG> for background of prior pallet <NUM> structures and <FIG> for examples of the present invention, a modular reconfigurable vehicle assembly pallet <NUM> and method <NUM> is shown. Where like components are discussed, the same numbers from <FIG> and <FIG> are used.

Referring to <FIG> and <FIG>, an example of the modular reconfigurable assembly pallet system <NUM> is shown. In the example shown in <FIG>, two modular plates <NUM> with respective risers <NUM> and locating pins <NUM> are positioned and secured on modular pallet <NUM> as generally shown. The example modular pallet system <NUM> shows two modular plates <NUM> and two additional fixed support beams <NUM> and respective risers <NUM> as generally shown. It is understood that pallet <NUM> can include more or fewer modular plates <NUM>, support beams <NUM> and/or risers <NUM> depending on the vehicle model being assembled, for example a first product or vehicle model and a second vehicle model, and the associated build specifications. In one example (not shown), no fixed support beams <NUM> are used and all of the risers <NUM> are provided by modular plates <NUM>.

In an alternate example (not shown) only one riser <NUM>, or more than two risers <NUM>, for each modular plate <NUM> may be used depending on the vehicle body configuration and assembly specifications may be used. It is further understood that locating pins <NUM> may take forms or constructions other than pointed cone structures as described and illustrated to engage one or more features of a partially completed vehicle or other product being assembled as understood by those skilled in the art. In a preferred example, pointed, cone shaped locating pins <NUM> are used to engage a hole in a sheet metal vehicle body component. It is further understood that risers <NUM> may take other forms other than the elongate risers having a body extending along the Z axis or coordinate direction <NUM> with the locating pins <NUM> at an apex of the riser <NUM>. For example, risers <NUM> may take many other forms, sizes, shapes, lengths and configurations suitable to position the locating pins <NUM> (or other physical product or vehicle positioning structure) to accommodate the product or vehicle feature to engage and/or position the product or vehicle in a predetermined X (<NUM>), Y (<NUM>) and Z (<NUM>) geometric coordinate directions or position.

In an example, pallet <NUM> is a common or universal constructed pallet which remains the same construction, or substantially the same construction, regardless of the modular plates <NUM> configured for specific products or vehicle models that are used with the pallet <NUM>. It is understood that the pallet <NUM> can also vary in its construction and configuration. It is further understood that base or pallet <NUM>, including rails <NUM>, crossmembers <NUM> and other structures can be of different components, configurations, orientations, dimensions, and geometry than described and illustrated herein in order to suit the application. It is further understood that although described for assembly of passenger vehicles, the system <NUM> can be used to assemble other products and devices other than passenger vehicles where model change flexibility and high accuracy and precision of assembly are needed. In one example, a plurality of first modular plates <NUM> are constructed and configured to engage and position an assembly sequence of first vehicle models and a plurality of second modular plates <NUM> are constructed and configured to engage and position an assembly sequence of second vehicle models. For example, the risers <NUM> for the second modular plates <NUM> may be spaced further from each other along the X coordinate direction <NUM>, and other risers <NUM>, then the first modular plate <NUM>, where the second vehicle model has a longer wheelbase than the first vehicle model.

Referring to <FIG> an example of a modular plate <NUM> for use with the reconfigurable pallet <NUM> is shown (without risers <NUM>). In the example, modular plate <NUM> includes a substantially planar plate <NUM> having a length <NUM> and width <NUM> as generally shown. In one example, length <NUM> is about <NUM> millimeters (mm) and the width <NUM> is about <NUM> millimeters (mm). In one example, plate <NUM> is a sheet of aluminum having a thickness of <NUM> to <NUM> millimeters (mm). Other widths, lengths, thicknesses, and materials may be used to suit the particular application and performance specifications.

As described above, in a preferred example, modular plate <NUM> is preassembled with a plate <NUM> including a pair of risers <NUM> having riser locating members, for example locating pins <NUM>, secured to plate <NUM> at machined locating pads <NUM> on the upper surface of plate <NUM>. In a preferred example, the respective locating pads <NUM> and risers are positioned in predetermined X (<NUM>) and Y (<NUM>) coordinate locations on the plate <NUM> for a specific vehicle model or style, for example a first vehicle model and a second vehicle model. The locating pads <NUM> and risers <NUM> can be positioned anywhere along the plate <NUM> in the longitudinal axis <NUM> (X coordinate direction) and lateral axis <NUM> (Y coordinate direction) to suit the particular vehicle model application with a high level of precision and accuracy, for example +/- <NUM> - <NUM> millimeters (mm). Other higher or lower levels of accuracy may be used depending on the application or performance specification.

In one example, the risers <NUM> are oriented on the locating pad <NUM> so that the centerline of the riser locating member or pin <NUM> is positioned in a predetermined design location relative to the plate, for example through use of a coordinate measuring machine (CMM). For example, a first modular plate <NUM> is configured with risers positioned on plate <NUM> in positions and/or spacing to specifically coordinate and engage with the first vehicle model once the plate <NUM> is installed on universal pallet <NUM>. Similarly, a second modular plate <NUM> would be configured with risers to coordinate and engage with the second vehicle model once the plate is installed on universal pallet <NUM>. Once positioned, the mounting bolts <NUM> and locking dowel <NUM> are secured rigidly mounting the riser <NUM> to the plate <NUM> as previously described thereby positioning the locating pin <NUM> in the proper design coordinate X, Y and Z positions on installation with universal pallet <NUM> for that specific vehicle model.

In the example shown in <FIG>, modular plate <NUM> includes a plurality of support pads <NUM> (six shown) extending outward along the X coordinate direction22. In the example, support pads <NUM> are integral with plate <NUM>. Other devices, sizes, shapes and configurations may be used. In the example, four large through apertures <NUM> are shown in plate <NUM> which may be used to reduce the weight of the modular plate. Apertures <NUM> can include different numbers and configurations, or could be eliminated from use where weight reduction is not necessary.

Referring to <FIG> an example of installation and removal of modular plate <NUM> from pallet <NUM> through use of a programmable, multi-axis industrial robot <NUM> is shown. In the example, robot <NUM> includes an end effector in the form of a frame <NUM> which selectively engages the modular plate <NUM> and positions it on pallet <NUM> for use as further discussed below.

Referring to <FIG>, the exemplary modular plate <NUM> is shown installed and secured to pallet <NUM> through use of six receivers <NUM>, <NUM> and <NUM> as generally shown and further discussed below.

Referring to the <FIG> right side view (no risers <NUM> shown), the exemplary modular plate <NUM> is shown installed on the pallet <NUM> through engagement with a first receiver <NUM> (a portion of second receiver <NUM> positioned behind also in view) and a third receiver <NUM>. Engagement of the modular plate <NUM> with the respective receivers is further discussed below.

<FIG> shows an end view of <FIG> with the modular plate <NUM> (with risers <NUM>) installed and secured to pallet <NUM>.

Referring to <FIG>, <FIG> and <FIG>, an example of the first plate locator <NUM> for use in supporting modular plate <NUM> along the longitudinal axis <NUM> (X coordinate direction) and the vertical axis <NUM> (Z coordinate direction) is shown. In the example, first plate locators <NUM> are rigidly secured to support pads <NUM> of modular plate <NUM> preferably through bolts (not shown) so the locators <NUM> can be replaced if worn or damaged through use. Preferably, support pad <NUM> of modular plate <NUM> is precision machined to provide a clean, planar surface to accurately position first locator <NUM> relative to the plate <NUM> and risers <NUM>.

In the example, first plate locator <NUM> includes base <NUM>, mounting holes <NUM>, a bore <NUM> extending laterally along lateral axis <NUM> (Y coordinate direction) into base <NUM> and an upright portion <NUM> having an inner surface <NUM>, outer surface <NUM>, upper surface <NUM> and a lower surface <NUM> as generally shown. Preferably, the inner <NUM>, outer <NUM>, upper <NUM> and lower <NUM> surfaces are machined surfaces to close dimensional tolerances or cast with high accuracy and precision. First locator <NUM> is shown used in two positions on plate <NUM> as best shown in <FIG> and selectively engage respective first receiver <NUM> as described further below.

Referring to <FIG>, <FIG> and <FIG>, an example of a second plate locator <NUM> for use in supporting the modular plate <NUM> along the lateral axis <NUM> (Y coordinate direction) and the vertical axis <NUM> (Z coordinate direction). In one example, a single second plate locator <NUM> is connected to plate <NUM> in coordination with a second receiver <NUM> as further discussed below. In the example, second locator <NUM> includes a base <NUM>, mounting holes <NUM>, a lateral bore <NUM> similar to bore <NUM> described above, a locking aperture <NUM> extending downward into base <NUM>, an upright portion <NUM> having an upper surface <NUM> and a lower surface <NUM> as generally shown. Second locator <NUM> selectively and removably engages second receiver <NUM> as shown and described further below. Referring to <FIG> an example of a third plate locator <NUM> shown mounted to modular plate <NUM> support pad <NUM> for use in supporting modular plate <NUM> in the vertical axis (Z coordinate direction) is shown. In the example, third plate locator <NUM> includes a base <NUM>, mounting holes <NUM>, a bore <NUM> along the lateral axis <NUM>, an upright portion <NUM> defining an upper surface <NUM> and a lower surface <NUM> as generally shown. Third plate locator <NUM> may further be of the same configuration and construction as first plate locator <NUM>. In an alternate example (not shown), all of the locators <NUM>, <NUM> and <NUM> may be of the same configuration, for example all including a locking aperture <NUM>, or other features for commonality purposes.

In the example, first <NUM>, second <NUM> and third <NUM> plate the support pads can be integral with the plate are secured to plate <NUM> and respective support pads <NUM> through bolts (not shown), other mechanical fasteners, or can be semi-permanently mounted through welding or other ways as understood by those skilled in the field. Plate locators <NUM>, <NUM> and <NUM> are preferably made from hardened steel for abrasion resistance or other materials suitable for the particular application. It is also understood that plate locators <NUM>, <NUM> and <NUM> may be an integral portion of modular plate <NUM>. It is understood that first <NUM>, second <NUM> and third <NUM> plate locators can have different sizes, shapes, dimensions, configurations as well as numbers and positional location on plate <NUM> other than those shown as known by those skilled in the field.

Referring to <FIG> and <FIG>, an example of first receiver <NUM> is illustrated. In the example, first receiver <NUM> includes a base <NUM> removably mounted to a pallet rail <NUM> (or crossmember <NUM> not shown) through bolts, other mechanical fasteners or semi-permanent methods such as welding. Exemplary first receiver <NUM> preferably includes a stationary arm <NUM> having an outer <NUM>, upper <NUM> and inner <NUM> portions as generally shown. The arm <NUM> defines a first receiver cavity <NUM> for receipt of a plate locator discussed further below. In a preferred example, first receiver <NUM> includes a plurality of bearing surfaces to engage and position a plate locator in the first receiver cavity <NUM>. In one example of the plurality of bearing surfaces, a first or outer roller <NUM>, a second or upper roller <NUM>, a third or inner roller <NUM> and a fourth or lower roller <NUM> is used. In the example, each roller <NUM>, <NUM>, <NUM> and <NUM> each including a respective axle <NUM> and an axis of rotation <NUM> relative to base <NUM> wherein a portion of each roller extends into the first receiver cavity (see <FIG>). Base <NUM> and arm <NUM> are preferably made from hardened steel for strength, dimensional accuracy and abrasion resistance. Other sizes, shapes, configurations, numbers, orientations and materials may be used as known by those skilled in the field.

In a preferred example, outer <NUM>, upper <NUM>, inner <NUM> and lower <NUM> rollers are rigidly and rotatably secured to respective base <NUM> or arm <NUM> and are made from hardened steel for dimensional accuracy, abrasion and wear resistance. In a preferred example, outer <NUM>, upper <NUM>, inner <NUM> and lower <NUM> rollers are permanently mounted to the respective base <NUM> and arm <NUM> so as to maintain accurate and precise positioning with respect to the pallet <NUM>, first locator <NUM> and modular plate <NUM>. It is understood that different sizes, shapes, configurations, numbers, orientations and materials for rollers <NUM>, <NUM>, <NUM> and <NUM> may be used as understood by those skilled in the field. It is further understood that one or more of exemplary bearing surfaces in the form of rollers <NUM>, <NUM>, <NUM> and <NUM> may be replaced with non-roller devices, for example stationary bearing surfaces, for example high-wear resistant plates and other devices known by those skilled in the art.

In a preferred example as best seen in <FIG>, on installation of modular plate <NUM> onto pallet <NUM> and the first <NUM>, second <NUM> and third <NUM> receivers, first plate locator <NUM> is positioned in the first receiver cavity <NUM> relative to the first receiver <NUM> as shown. In the example, first plate locator <NUM> inner surface <NUM> is in direct contact and rolling engagement with inner roller <NUM>, outer surface <NUM> is in direct contact and rolling engagement with first receiver <NUM> outer roller <NUM>, upper surface <NUM> is in direct contact and rolling engagement with upper roller <NUM> and lower surface <NUM> is in direct contact and rolling engagement with lower roller <NUM>. These structures operate to position modular plate <NUM> in a predetermined X (<NUM>) and Z (<NUM>) coordinate directions relative to the pallet <NUM>. The predetermined X (<NUM>) and Z (<NUM>) position of the modular plate <NUM> relative to the pallet <NUM> effectively positions the riser <NUM> locating pin <NUM> in an accurate and precise predetermined X (<NUM>) and Z (<NUM>) coordinate position that is specific to a predetermined product or vehicle model, for example a first vehicle model. This effectively configures or customizes assembly pallet <NUM> to coordinate and engage the specific product or vehicle model being assembled. On the described engagement between the exemplary receiver rollers and the plate locators, the engagement prevents, or substantially prevents, relative movement of modular plate <NUM> along the longitudinal axis <NUM> (X coordinate direction) and along the vertical axis <NUM> (Z coordinate direction) relative to the pallet <NUM> while allowing first locator <NUM> and modular plate <NUM> to move along the lateral axis <NUM> (Y coordinate direction) during installation and removal of modular plate <NUM> from pallet <NUM> as further described below.

Referring to <FIG>, an example of a second receiver <NUM> for selectively receiving and securing second locator <NUM> and modular plate <NUM> to pallet <NUM> is shown and described below. In the example best seen in <FIG>, second receiver <NUM> includes a base <NUM> having a fork <NUM> defining a slot <NUM>. An arm <NUM> is positioned in the slot <NUM> and rotatably secured by a pivot pin <NUM> allowing arm <NUM> to rotate about an axis of rotation <NUM> from a first disengaged position (<FIG>) to a second engaged position (shown in <FIG> and <FIG>) relative to base <NUM>. The arm <NUM> and/or the base <NUM> define a second receiver cavity <NUM> for receipt of a plate locator as further described below.

As best seen in <FIG>, second receiver <NUM> preferably includes at least one (two shown) bearing surfaces for engagement with a plate locator. In the example, the at least one bearing surface includes an upper or first roller <NUM> and a lower or second roller <NUM> rotatably secured to the respective base <NUM> or arm <NUM> through a respective axle about an axis of rotation. As with first receiver <NUM>, each roller <NUM> and <NUM> includes a portion extending into the second receiver cavity <NUM>. Upper <NUM> and lower <NUM> rollers are preferably secured and made from the same materials as the rollers described for first receiver <NUM> above. Second receiver <NUM> may be made from the same materials as the first receiver <NUM> described above. It is understood that different sizes, shapes configurations, orientations, numbers and materials for the receiver <NUM> and bearing surfaces may be used as known by those skilled in the art. For example, one or more of the rollers <NUM> and <NUM> may be replaced by stationary wear resistant plates as described for first receiver <NUM>.

In a preferred example, second receiver <NUM> includes a locking pin <NUM> connected to rotatable arm <NUM>. Locking pin <NUM> preferably has an upper portion <NUM> connected to arm <NUM> and a downwardly extending lower portion <NUM> which is selectively positioned down into the locking aperture <NUM> of the second locator <NUM> when arm <NUM> is in a second position as shown in <FIG> and <FIG>. In this second position with locking pin <NUM> positioned down into locking aperture <NUM>, upper roller <NUM> is in direct contact and in rolling engagement with the second plate locator <NUM> upper surface <NUM> and lower roller <NUM> is in direct contact and rolling engagement with lower surface <NUM> as generally shown. In this arm <NUM> second position, the second locator <NUM> and modular plate <NUM> are positioned in a predetermined a predetermined Y (<NUM>) and Z (<NUM>) coordinate directions relative to the pallet <NUM>. The predetermined Y (<NUM>) and Z (<NUM>) position of the modular plate <NUM> relative to the pallet <NUM> effectively positions the risers <NUM> locating pins <NUM> in an accurate and precise predetermined Y (<NUM>) and Z (<NUM>) coordinate position that is specific to a predetermined product or vehicle model, for example a first vehicle model. This effectively configures or customizes assembly pallet <NUM> to coordinate and engage the specific product or vehicle model being assembled. prevented, or substantially prevented, from movement relative to second receiver <NUM> along the lateral axis <NUM> (Y coordinate direction) and the vertical axis <NUM> (Z coordinate direction). In one example not shown, second receiver <NUM> may eliminate the rollers <NUM> and <NUM> and rely only on positioning and securing modular plate <NUM> in the Y coordinate direction <NUM> through locking pin <NUM> as described.

Referring to <FIG>, the first or disengaged position of second receiver <NUM> arm <NUM> is shown. In the example in the second position, arm <NUM> is rotated about axis of rotation <NUM> such that locking pin <NUM> is removed from locking aperture <NUM> in the second plate locator <NUM> as generally shown. In this first disengaged position, second locator <NUM> and modular plate <NUM> may move relative to second receiver <NUM> and pallet <NUM> along the lateral axis <NUM> (Y coordinate direction), for example when the modular plate <NUM> is being installed or removed from pallet <NUM>. In a preferred example, second receiver <NUM> is normally positioned or biased to be in the second or engaged/locked position to orient locking pin <NUM> into locking aperture <NUM>. This example ensures that if a modular plate <NUM> is installed on pallet <NUM>, the modular plate <NUM> is prevented from movement along the lateral axis <NUM>. A biasing device, for example a spring or detent (not shown) may be used to bias or force arm <NUM> toward the second engaged position as described. Other biasing or detent devices or features, for example pneumatic, magnetic, or other devices known by those skilled in the art may be used. It is also understood that arm <NUM> may be normally biased toward the first disengaged position and moved toward the second position or simply oriented to the second position under the force of gravity or other biasing device as described and as otherwise known by those skilled in the art.

In a preferred example best seen in <FIG>, <FIG> and <FIG>, second receiver <NUM> arm <NUM> includes a cam roller <NUM> extending inward toward plate <NUM> as generally shown. In a preferred example, modular pallet system <NUM> end effector <NUM> includes a guide <NUM> connected to the end effector <NUM> as further described below. Exemplary guide <NUM> includes a longitudinal, contoured track or slot <NUM> extending along the lateral axis <NUM> as best seen in <FIG>. Track <NUM> includes an open end <NUM> whereby cam roller <NUM> can enter and exit the track <NUM> when the end effector <NUM> and guide <NUM> are positioned adjacent one another and end effector <NUM> is moved along the lateral axis <NUM> (Y coordinate direction).

Referring to <FIG> and <FIG>, in a preferred example, on installation of a modular plate <NUM> to pallet <NUM>, end effector <NUM> and guide <NUM> are positioned along the longitudinal <NUM> (X), lateral <NUM> (Y) and vertical <NUM> (Z) positions such that the first <NUM>, second <NUM> and third <NUM> plate locators are aligned or in proximity to respective first <NUM>, second <NUM> and third <NUM> receivers. In this position, guide <NUM> slot opening <NUM> is aligned with cam roller <NUM> in arm <NUM> first position as generally shown in <FIG>. As robot <NUM>, end effector <NUM> and modular plate <NUM> continue movement along the lateral axis <NUM> toward a full or secured installation position, contoured track <NUM> angles upward as shown in <FIG> thereby forcibly raising cam roller <NUM> and arm <NUM> upward toward the arm first disengaged position as described above and shown in <FIG> prior to second locator <NUM> reaching the second receiver <NUM> so as to clear locking pin <NUM> from contacting second plate locator <NUM>. On reversal of movement of robot <NUM>, end effector <NUM> and guide <NUM> along the lateral axis <NUM>, cam roller <NUM>, arm <NUM> and locking pin <NUM> are returned to their second engaged position wherein the locking pin <NUM> is re-positioned in locking aperture <NUM> thereby locking the modular plate <NUM> from movement along the lateral axis <NUM> (Y coordinate direction) relative to second receiver <NUM> and pallet <NUM>.

It is understood that guide <NUM> and track <NUM> may take other forms, configurations, numbers and orientations as known by those skilled in the art. It is also included that a secondary locking device (not shown) may be used to further lockingly secure modular plate <NUM> to pallet <NUM> preventing movement along the lateral axis <NUM> or other axes <NUM> and <NUM>.

Although second receiver <NUM> arm <NUM> is described as being rotatable from a first disengaged position to a second engaged position in order to engage or disengage locking pin <NUM> from locking aperture <NUM>, it is understood that other devices and methods can be used in order to insert locking pin <NUM> into locking aperture <NUM>. For example, a linear slide device or arm may be used instead of the rotating arm <NUM> as described. Other devices and methods for preventing modular plate <NUM> from moving in the lateral axis direction (Y coordinate direction) relative to pallet <NUM> known by those skilled in the art may be used.

Referring to <FIG>, <FIG>, an example of a third receiver <NUM> for use in modular reconfigurable pallet system <NUM> is illustrated. In one example as best seen in <FIG> and <FIG>, three third receivers <NUM> are positioned on respective rails <NUM> or a pallet center support to receive and secure third plate locator <NUM> and modular plate <NUM> to pallet <NUM>. As shown in <FIG>, the third receivers <NUM> are all positioned on one side opposite the first <NUM> and second <NUM> receivers. It is understood that different locations for the third receivers <NUM> may be used.

As best seen in Figs. 14A, <FIG>, exemplary third receiver <NUM> includes a base <NUM> and an arm <NUM>. In the example, arm <NUM> defines a third receiver cavity <NUM> for receipt of a plate locator described below. Exemplary third receiver <NUM> includes at least one bearing surface for engagement with a locator positioned in the third receiver cavity <NUM>. In the example, the at least one bearing surface includes an upper or first roller <NUM> and a lower or second roller <NUM> as generally shown. In the example, base <NUM> is mounted to a rail <NUM> or pallet center structure through bolts, other mechanical fasteners or semi-permanent attachment methods such as welding.

As best seen in <FIG>, on installation of modular plate <NUM> and third plate locator <NUM>, upper roller <NUM> is in direct contact and rolling engagement with third locator upper surface <NUM> and lower roller <NUM> is in direct contact and rolling engagement with lower surface <NUM> as generally shown. In this position, the modular plate <NUM> is positioned in a predetermined a predetermined Z (<NUM>) coordinate direction relative to the pallet <NUM>. The predetermined Z coordinate (<NUM>) position of the modular plate <NUM> relative to the pallet <NUM> effectively further positions the risers <NUM> locating pins <NUM> in an accurate and precise predetermined Z coordinate (<NUM>) position that is specific to a predetermined product or vehicle model, for example a first vehicle model. This effectively configures or customizes assembly pallet <NUM> to coordinate and engage the specific product or vehicle model being assembled. In this position, the third plate locator <NUM> and modular plate <NUM> are prevented, or substantially prevented, from movement along the vertical axis <NUM> (Z coordinate direction) relative to third receiver <NUM> and pallet <NUM>. Rollers <NUM> and <NUM> may be made from the same materials and secured to the respective base <NUM> an arm <NUM> as the rollers for the first <NUM> and second <NUM> receivers as described above. As noted above, the at least one bearing surface may take forms other than the described two rollers, for example wear-resistant skid plates, which abut the third locator <NUM>. The third receiver may be made from the same materials and include variations described above for the first receiver <NUM>. As described, the third receivers <NUM> can take the form as described for the first receiver <NUM>.

In one example of modular pallet system <NUM>, a plurality of electronic sensors (not shown) may be employed to monitor the state or position of an individual component or position of engagement between two components. For example, one or more sensors may be used between the plurality of plate locators <NUM>, <NUM> and <NUM> and the respective plurality of receivers <NUM>, <NUM> and <NUM> to determine or monitor whether the locators are properly positioned in the respective receiver. In another example, a sensor may be used to determine whether second receiver <NUM> arm <NUM> is in the first disengaged or second engaged position. Alternately, or in addition to, a sensor may be used to determine or monitor whether locking pin <NUM> is positioned in locking aperture <NUM>. The exemplary sensors may be electronic through wires or wireless protocols to send signals to computers, processors and/or servers in local, central or remote monitoring stations for monitoring by human operators. The electronic sensors may be of other forms, for example optical or vision sensors. Other sensors and monitoring devices and/or systems may be used as known by those skilled in the art.

Referring to <FIG>, <FIG> and <FIG>, an example of end effector <NUM> for engaging and transferring modular plate <NUM>, and a plurality of different modular plates <NUM>, for example a first and a second modular plate configured for different products or vehicle bodies, is shown. In the example, end effector <NUM> includes a connector <NUM> engageable with a wrist or mounting plate of robot <NUM>. Exemplary end effector <NUM> includes a first arm <NUM> and an opposing second arm <NUM> as generally shown. As best seen in <FIG>, <FIG> and <FIG>, in one example, guide <NUM> is connected to the end of first arm <NUM> opposite connector <NUM>.

In the example as best seen in <FIG>, <FIG> and <FIG>, each of the end effector <NUM> first <NUM> and second <NUM> arms have two modular plate connectors <NUM>. Each exemplary plate connector <NUM> includes a mounting block <NUM> connected to the respective arm <NUM>, <NUM>, a pin block <NUM> connected to the mounting block, and a transfer pin <NUM> extending outwardly from the pin block along the lateral axis <NUM> (as illustrated). The transfer pins <NUM> are sized and oriented to selectively enter four of the respective first <NUM>, second <NUM>, and third <NUM> plate locator bores <NUM>, <NUM> and <NUM> to engage modular plate <NUM> to end effector <NUM> and robot <NUM>.

In the example shown, arms <NUM> and <NUM> only engage the first two pairs of locators (shown to the left in <FIG>) located closest to the robot <NUM>. On engagement of the modular plate to the end effector <NUM> and robot <NUM>, modular plate <NUM> may be oriented and positioned so as to align and engage the first <NUM>, second <NUM> and third <NUM> plate locators with the respective first <NUM>, second <NUM> and third <NUM> receivers through further movement of the modular plate <NUM> along the lateral axis <NUM> to engage the receivers as described above. It is understood that other devices and methods for engaging end effector <NUM> with modular plate <NUM>, or engaging robot <NUM> to modular plate <NUM>, may be used by those skilled in the art. For example, end effector <NUM> can engage fewer or more of the first <NUM>, second <NUM> and third <NUM> locators and through different structures or methods than the plate connectors <NUM>. Although robots <NUM> are shown to engage and manipulate modular plates <NUM>, other devices, for example forklifts, or other equipment may be used to engage, move and position plate <NUM> relative to pallet <NUM>, as known by those skilled in the art.

Through engagement of the first <NUM>, second <NUM>, third <NUM> plate locators with the respective first <NUM>, second <NUM> and third <NUM> receivers, the modular plate <NUM>, and risers <NUM> positioned thereon, are positioned in predetermined positions specific to a product or vehicle model as described above and secured from movement in all three axes <NUM>, <NUM> and <NUM> (all X, Y and Z coordinate directions) from movement relative to pallet <NUM>. Through the process of prefabricating plate <NUM> and mounting of risers <NUM> thereon as described above, in a preferred example, this secured or locked position of vehicle model specific modular plate <NUM> to pallet <NUM> is capable of positioning the locating pins <NUM> within +/- <NUM> - <NUM> millimeters (mm) from a design or predetermined <NUM>-dimensional X (<NUM>), Y (<NUM>) and Z (<NUM>) coordinate position for specific products or vehicle models. Levels of dimensional accuracy and precision above and below this range may be achieved as known by those skilled in the art.

To remove the engaged modular plate <NUM> from pallet <NUM>, end effector <NUM> is positioned so that transfer pins <NUM> are engaged with the respective locators, and guide <NUM> has engaged cam roller <NUM> thereby raising arm <NUM> to its first disengaged position thereby removing locking pin <NUM> from locking aperture <NUM>. Slight upward movement or force by the robot <NUM> in the Z axis or direction <NUM> frictionally engages the end effector <NUM> to the plate <NUM> through the transfer pins <NUM>. In the preferred example, this position permits movement of the modular plate <NUM> along the lateral axis <NUM> (Y coordinate direction). Once arm <NUM> is in a first or disengaged position from second locator <NUM>, robot <NUM> and end effector <NUM> may be moved along the lateral axis <NUM> until the locators are disengaged from the respective receivers and the modular plate <NUM> can be vertically raised, removed from pallet <NUM> and relocated to an adjacent modular plate <NUM> storage rack, or moved to a different location, for example by placement of the modular plate <NUM> on an automated guided vehicle (AGV) or automated guided cart (AGC) for transport to a remote or centralized storage area in the assembly facility.

Referring to <FIG> and <FIG>, one example application of modular reconfigurable assembly pallet system <NUM> is shown. In the example, four robots <NUM> are used, two robots <NUM> positioned on either side of an assembly or pallet transfer line. As best seen in the example shown in <FIG>, one or both sides of the transfer line includes a storage device or rack <NUM> (shown on one side only) including multiple shelves for supporting and storing a plurality of modular plates <NUM> for at least a first vehicle model and preferably at least a second product or vehicle model. In one example, a plurality of first modular plates <NUM> including risers <NUM> and locating pins <NUM> having a position and geometry specific to a first vehicle model A are stored or racked on one side of the transfer line in storage rack <NUM> and a plurality of second modular plates 94A specific to a second vehicle model B are positioned on the other side of the transfer line. In one example, pallets <NUM> moving down the transfer line can be selectively equipped with the appropriate modular plate(s) <NUM> or 94A to coordinate with the predetermined assembly line product or vehicle body assembly sequence in real time. In an alternate example, each storage rack <NUM> may store a plurality of different modular plates <NUM> for a plurality of different vehicle models or products to be assembled. As the type of vehicle models in the assembly sequence changes, the robots <NUM> can remove the installed modular plate, for example a first modular plate <NUM>, with a second modular plate 94A to accommodate the change in the type or model of vehicle to be assembled.

Alternately, a predetermined number of pallets <NUM> with first modular plates <NUM> and/or second modular plates 94A can be configured in a separate pallet configuration line or area and transitioned into an assembly sequence. This provides a substantial improvement and flexibility over present vehicle assembly pallet systems which either were custom made for a single vehicle style or had limited adjustability in a length direction, but were limited to the same locator pin type. The modular reconfigurable assembly pallet <NUM> can use a standard or universal pallet <NUM> for all vehicle models and only the modular plates <NUM> having vehicle (or product) specific riser positions and riser locator members or pins <NUM> need be fabricated and installed on an as needed basis to support production. This flexibility enables vehicle and other product manufacturers to change model style assembly sequences, for example random, or more random, A,A,A,B,B, A,B,A versus more common batch build sequences A,A,A,A,A,B,B,B,B,B. The present system <NUM> further provides increased flexibility for semi-permanent plant model changeover or intermittent production changes, for example executing a limited, small quantity test run of vehicles for process validation. Other uses and advantages of the increased flexibility and efficiencies in fabrication are achievable as known by those skilled in the art.

Referring to <FIG> a flow chart of an exemplary method <NUM> (not covered by the present invention) of providing and using modular reconfigurable pallet system <NUM> is shown. In providing a modular reconfigurable vehicle pallet assembly <NUM>, the first step <NUM> fabricates a standard or universal pallet <NUM> as described above. This may include one or more fixed support beams <NUM> and risers <NUM> described above depending on the product or vehicle model and level of flexibility required by the manufacturer. In one example, a plurality of receivers, for example first <NUM>, second <NUM> and third <NUM>, are mounted to the pallet <NUM> in locations to receive the locators mounted to modular plate <NUM>.

In a second step <NUM>, the vehicle-specific support points through risers <NUM> and locating pins <NUM> are identified and the number and model of modular plates <NUM> is identified. The X (<NUM>), Y (<NUM>) and Z (<NUM>) coordinate position or location of risers <NUM> and locating pins <NUM> specific to the respective vehicle model is identified. One, or a plurality of, modular plates <NUM> specific to that vehicle model are fabricated. Positioning and securing the risers <NUM> and riser locating members <NUM>, preferably pins, relative to plate <NUM> is preferably made through machined locating pads <NUM>, mounting bolts <NUM> and locking bolt or dowels <NUM> as described above. A plurality of plate locators, for example first <NUM>, second <NUM> and third <NUM>, are connected to each plate <NUM>.

When an assembly pallet <NUM> is needed for a particular vehicle body, a modular plate <NUM> having that vehicle model configured riser <NUM> and riser locating members <NUM> is in step <NUM> moved in proximity to the pallet <NUM> and respective receivers for installation on pallet <NUM>. In one example, a robot <NUM> and end effector <NUM> engage the modular plate <NUM> through transfer pins <NUM> to engage and support modular plate <NUM>.

In a preferred but optional step <NUM>, prior to full or locking engagement of modular plate <NUM> to pallet <NUM>, end effector <NUM> positions a guide <NUM> to engage a cam roller <NUM> on a second receiver arm <NUM> and through movement of the end effector <NUM> and engaged modular plate <NUM> along the lateral axis <NUM>, the second receiver arm <NUM> is moved to a first disengaged position thereby providing clearance for the second locator <NUM> to be installed in second receiver <NUM>. On retraction of end effector <NUM> along the lateral axis <NUM>, the cam roller <NUM> disengages from the guide <NUM> thereby returning the second receiver arm and locking pin <NUM> to the second engaged position into the locking aperture <NUM> in the second locator <NUM> thereby securing the modular plate <NUM> in the lateral axis <NUM> direction relative to the pallet <NUM>.

In step <NUM>, the assembly operation on the particular model of vehicle or product suited for the installed configuration of modular plate <NUM> is conducted. The assembly operation is repeated using modular plate <NUM> and pallet <NUM> until a change in the assembly sequence is ordered or, for example, the modular plate <NUM> needs to be changed for maintenance or repair.

In step <NUM>, on a need to reconfigure the modular pallet <NUM> for a different vehicle model, or for maintenance or repair of the modular plate <NUM>, the robot <NUM> and end effector <NUM> are positioned to re-engage modular plate <NUM> thereby moving the second receiver <NUM> into the second or disengaged position. The modular plate is moved in the lateral axis <NUM> direction thereby disengaging the locators from the respective receivers to remove the modular plate <NUM> from the pallet. On a change in the production assembly sequence to a second vehicle model, system <NUM> installs a second modular plate 94A to the pallet <NUM> thereby reconfiguring the pallet <NUM> to accommodate the different product or second vehicle body without having to replace the entire pallet <NUM> as in prior systems.

The relative ease and efficiency of fabricating the modular plates <NUM> for specific vehicles, versus dedicating the entire pallet <NUM> to a specific vehicle, is further improved by the greatly reduced storage of modular plates <NUM> versus the entire pallet <NUM> greatly improving plant logistics.

In addition to the substantially increased configuration flexibility, positional dimensional tolerances of the risers <NUM> and locating pins <NUM> can be maintained, if not improved, over prior assembly pallet systems.

In an example not shown, modular plate <NUM> can include vehicle or product model specific tooling other than risers <NUM> and riser locating members or pins <NUM> as described and illustrated. For example, modular plate <NUM> can instead include relatively low profile/height bushing-type locators or other structural locating devices mounted to modular plate <NUM> which engage a product or vehicle body instead of elongate risers <NUM> and riser locating members <NUM>.

Further, in an alternate example not shown, other forms of model or product specific tooling may be used on modular plate <NUM>, for example, holding clamps, electrical grounding devices and other structures that are specific to a vehicle or product model that is being assembled. In a similar manner as described above for a modular plate <NUM> including risers <NUM>, when the vehicle model or product assembly sequence is changed to a new product or vehicle, the model specific modular plate <NUM> is disengaged, removed and replaced on the pallet <NUM> or other supporting structure to accommodate the new vehicle model or product to be assembled.

Claim 1:
A system for reconfiguring an assembly pallet for use in the assembly of vehicle bodies, the system comprising:
a universal support pallet (<NUM>) having at least a first and a second receiver (<NUM>, <NUM>);
a plurality of plates (<NUM>) each having a plurality of plate locators (<NUM>);
the system being characterized in that it comprises:
a first modular plate (<NUM>) having a pre-mounted riser (<NUM>) specific to a first vehicle model, the riser (<NUM>) being connected to one of the plurality of plates (<NUM>) in a predetermined X and Y coordinate position specific to a first vehicle model (A);
a second modular plate (<NUM>) having a pre-mounted riser (<NUM>) specific to a second vehicle model, the riser (<NUM>) being connected to one of the plurality of plates (<NUM>) in a predetermined X and Y coordinate position specific to a second vehicle model (B),
wherein the predetermined X and Y coordinate position of the riser (<NUM>) of the first modular plate (<NUM>) is different than the second modular plate (<NUM>);
wherein the system is configured for transferring one of the first or the second modular plates (<NUM>) to the universal pallet (<NUM>); each of the first or the second modular plates (<NUM>) being configured to be engaged to the universal pallet (<NUM>) through engaging of the plurality of plate locators (<NUM>) with respective of the first and the second receivers (<NUM>, <NUM>) thereby positioning the riser (<NUM>) in a predetermined X, Y and Z coordinate position specific to the respective first or the second vehicle model (A, B).