DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] As shown in FIG. 1 , in one embodiment of the present invention, a component part installer 20 is provided. Component part installer 20 comprises a component part carrier 22 shiftably coupled to a supporting surface 24 via a carriage 26 and an arm assembly 28 .

[0024] Referring now to FIGS. 1 and 2 , supporting surface 24 can be any stable horizontal, vertical or angled surface capable of rigidly supporting the weight and torque imparted by component part carrier 22 , carriage 26 and arm assembly 28 . Preferably, supporting surface 12 is a substantially horizontal overhead surface. Supporting surface 24 can include overhead horizontally extending rails 30 . Rails 30 preferably extend in a substantially horizontal direction corresponding to the direction of travel of an assembly line. As best seen in FIG. 2 , rails 30 are substantially parallel to an assembly line track 32 which supports a vehicle body 34 via a suspension device 36 . Rails 30 are horizontally spaced from the track 32 and the vehicle body 34 so that component part carrier 22 can translate along the rails 30 and the arm assembly 28 can translate in and out of an opening, typically a door opening, in vehicle body 34 .

[0025] As best seen in FIG. 1 , carriage 26 is shiftably coupled to rails 30 by any means known in the art for providing translation of carriage 26 along rails 30 . Preferably, carriage 26 comprises a plurality of rollers 38 for providing translation along rails 30 . Carriage 26 further comprises a base 40 for rigidly supporting arm assembly 28 .

[0026] As best seen in FIG. 1 , arm assembly 28 is physically interposed between carriage 26 and component part carrier 22 . Assembly arm 28 provides translation of component part carrier 22 relative to carriage 26 . Arm assembly 28 also provides support for component part carrier 22 so that the downward force exerted on arm assembly 28 , due to the weight of component part carrier 22 , is at least partially counteracted by the upward bias of arm assembly 28 .

[0027] Arm assembly 28 comprises a first member 42 having a pivot end 44 and a swing end 46 . Pivot end 44 is pivotably coupled to base 40 so that swing end 46 can rotate about pivot end 44 . First member 42 preferably projects in a substantially horizontal direction so that swing end 46 can be rotated substantially horizontally about pivot end 44 . In addition, swing end 46 is preferably capable of vertical translation relative to pivot end 44 . Such vertical translation of swing end 46 can be provided by any means known in the art. For example, vertical translation of swing end 46 can be provided by a four-bar linkage assembly 48 . First member 42 can include a hinge 50 located between pivot end 44 and swing end 46 . Hinge 50 provides a substantially vertical pivot axis in first member 44 and allows swing end 46 to be rotated substantially horizontally relative to hinge 50 .

[0028] Arm assembly 28 further comprises a second member 52 having a first end 54 and a second end 56 . First end 54 is rotatably coupled to swing end 46 so that second member 52 can rotate around its longitudinal axis. Second member 52 is preferably maintained in a substantially upright position with first end 54 being spaced vertically higher than second end 56 . Four-bar linkage assembly 48 is preferably configured so that when swing end 46 translates vertically, second member 52 remains in a substantially upright position. In an alternative embodiment, not shown, second member 52 can comprise a four-bar linkage assembly for providing substantially horizontal translation of second end 56 relative to first end 54 .

[0029] Arm assembly 28 further comprises a third member 58 having a proximal end 60 and a distal end 62 . Proximal end 60 is fixedly attached to second end 56 . Distal end 62 is fixedly attached to component part carrier 22 . Third member 58 is preferably maintained in a substantially horizontal position during translation of component part carrier 22 . Third member 58 is preferably spaced vertically lower than first member 42 .

[0030] A translation force can be applied to arm assembly 28 by any means known in the art for providing horizontal and vertical movement of a mechanical arm. As shown in FIG. 2 , the translation force can be provided manually by an operator 64 to provide selective placement of the arm assembly relative to the part receiving platform. Alternatively, the translation force can be provided by suitable automatically controllable mechanical devices known in the art. Further, the path of translation of arm assembly 28 can be controlled manually by operator 64 , as shown in FIG. 2 , or by any suitable programmable automated device known in the art. Preferably, the translation force and translation path are provided by operator 64 who can inspect the vehicle body during part placement for quality assurance.

[0031] Referring back to FIG. 1 , component part carrier 22 is preferably a rigid frame capable of supporting a plurality of component parts 66 in a substantially fixed spatial relationship. Component part carrier 22 comprises an upper main member 68 , a plurality of legs 70 and a plurality of part receivers 72 . Each leg 70 has a proximal end fixedly attached to upper main member 68 , and a distal end fixedly attached to a respective part receiver 72 . Preferably, component part carrier 22 has four or more part receivers 72 , most preferably eight part receivers 72 . Each part receiver 72 is adapted for selectively holding and releasing a respective component part 66 . Each part receiver 72 preferably has at least one contact surface adapted to form a substantially flush fit with a portion of the surface of a respective component part 66 . Most preferably, each part receiver has at least two contact surfaces adapted to fit in registry with a surface of a respective component part 66 .

[0032] The contact surface of each part receiver is fluidically connected with a vacuum source circuit. The vacuum source circuit comprises a vacuum source 74 and a switch 76 . Switch 76 is selectively actuatable to commence and at least partially terminate the flow of air from part receivers 72 to vacuum source 74 , such as by permitting the flow of air into the vacuum source 74 directly at the switch 76 or at another location along the circuit. When switch 76 is actuated to commence the flow of air from part receivers 72 to vacuum source 74 and the contact surfaces of part receivers 72 are simultaneously contacted with respective component parts 66 , component parts 66 are temporarily attached to part receivers 72 by vacuum attachment. When switch 76 is actuated to at least partially discontinue the flow of air from part receivers 72 to vacuum source 74 , component parts 66 are released from part receivers 72 .

[0033] Vacuum source 74 can be any conventional air displacement device capable of creating a sufficient vacuum attachment force so that component parts 66 can be temporarily attached to part receivers 72 by vacuum attachment. As shown in the drawings, the vacuum source 74 is a vacuum pump coupled for movement with the carriage 26 , but alternatively the vacuum pump may be remotely located and connected by a length of flexible pneumatic tubing of sufficient length to connect to the carriage 26 and permit the carriage 26 to move along the rails 30 .

[0034] Switch 76 is preferably manually actuatable by the operator and is fluidly interposed between vacuum source 74 and part receivers 72 . Switch 76 may be any conventional electrical or pneumatic control device that is selectively actuatable to at least partially discontinue the flow of air from part receivers 72 to vacuum source 74 . Preferably, switch 76 is a pneumatic switch.

[0035] Switch 76 is preferably mounted on a manifold 78 . Manifold 78 is fixedly attached to second member 52 . Manifold 78 is fluidly interposed between vacuum source 74 and part receivers 72 . Manifold 78 is fluidically coupled to vacuum source 74 via at least one trunk line 80 . Manifold 78 is fluidically coupled to part receivers 72 via a plurality of feeder lines 82 . Manifold 78 is adapted to distribute the negative pressure created in trunk lines 80 by vacuum source 74 substantially evenly among feeder lines 82 so that each part receiver 72 exerts a substantially equal vacuum attachment force on each respective component part 66 .

[0036] A handle 84 is preferably mounted on manifold 78 in close proximity to switch 76 . Handle 84 facilitates manual translation of component part carrier 22 . Further, handle 84 is positioned so that switch 76 can be actuated by human hands without releasing handle 84 .

[0037] Component part installer 20 can further comprise a counter-force device 86 . Counter-force device 86 provides a stabilizing, lifting force which acts on the arm assembly 28 to which it is connected. Preferably, the upward bias of arm assembly 28 at least partially counteracts the downward force exerted on arm assembly 28 by the weight of arm assembly 28 , component part carrier 22 , and component parts 66 . Counter-force device 86 is preferably mounted on first member 42 so that an upward bias is provided to swing end 46 relative to pivot end 44 . Counter-force device 86 can be coupled to a portion of first member 42 which extends vertically above four-bar linkage assembly 48 . In this configuration, counter-force device 86 provides an upward bias to swing end 46 by pulling upward on the top member of four-bar linkage assembly 48 . As best seen in FIG. 2 , counter-force device 64 preferably provides sufficient upward bias on first member 42 such that an operator 64 can repeatedly facilitate the translation of component part carrier 22 in both horizontal and vertical directions without exerting a human-fatiguing translation force. The counter-force device 64 may be a simple spring or other device well known to those skilled in the art.

[0038] In an alternative embodiment, not shown, counter-force device 86 can be interposed at an angle between the upper and lower substantially horizontal members of four-bar linkage 48 . In such an alternative embodiment, counter-force device 86 is preferably placed at an angle such that the end of counter-force device 86 connected to the upper substantially horizontal member of four-bar linkage assembly 48 is positioned closer to swing end 46 than the end of counter-force device 86 connected to the lower substantially horizontally projecting member of four-bar linkage assembly 48 .

[0039] FIGS. 2 - 5 , shown in a preferred embodiment of the present invention of, the installation of a plurality of component parts 66 in a platform 88 . As best seen in FIGS. 3 - 5 , platform 88 may be the floor of vehicle body 34 having a plurality of part reception sites 90 . Part reception sites 90 have a fixed spatial relationship to each other. Part reception sites 90 illustrated herein are cavities in the floor pan of vehicle body 34 where seat anchoring devices extend upward from under the floor pan. The spatial relationship of part reception sites 70 is substantially the same as the spatial relationship of part receivers 72 .

[0040] By way of an example of one type of part which may be installed in accordance with the present invention, FIGS. 6 - 10 show component part 66 as a one-piece thermally expandable, flexible sealing member which is configured to correspond to the overall shape and size of part reception sites 90 . Of course, the part receivers 72 may be configured to hold and install other parts, the flexible sealing member illustrated being only one example thereof. In more detail, the illustrated component part 66 comprises a substantially rectangular lip 92 , sidewalls 94 a,b , end walls 96 a,b , bottom portions 98 a,b, and an opening 100 . Sidewalls 94 a,b and endwalls 96 a,b extend downwardly from an inner periphery 102 of lip 92 to bottom portions 98 a,b . Opening 100 separates bottom portions 98 a,b . Bottom portions 98 a,b comprise upper surfaces 104 a,b which are substantially flat along a plane which is substantially parallel to that of lip 92 . Component part 66 is preferably formed of a thermoplastic material. More preferably, component part 66 is formed of a polymeric base which includes ethylene vinyl acetate (EVA) and an elastomer.

[0041] Referring back to FIGS. 1 - 5 , to simultaneously install multiple component parts 66 in reception sites 90 , component part carrier 10 must first be loaded with component parts 66 . While component part carrier 22 is retracted from vehicle body 34 , as shown in FIG. 3 , upper surfaces 104 a,b of component part 66 , shown in FIG. 6 , are contacted with contact surfaces of part receivers 72 . The flow of air from the part receivers 72 to the vacuum source 74 temporarily attaches component parts 66 to part receivers 72 by vacuum attachment.

[0042] While component parts 66 are attached to part receivers 72 by a vacuum attachment, operator 64 , shown in FIG. 2 , translates the carriage 26 along its rails 30 to follow the movement of the vehicle body 34 along its track 32 and shifts the component part carrier 22 from a retracted position, shown in FIG. 3 , to a position adjacent to an opening in vehicle body 34 , shown in FIG. 4 . As best shown in FIGS. 2 and 5 , operator 64 translates component part carrier 22 through the opening in vehicle body 34 and into the interior of vehicle body 34 . The component part carrier is positioned so that component parts 66 are substantially aligned with part reception sites 90 . Component part carrier 22 is then lowered so that component parts 66 are in registry with corresponding part reception sites 90 . Advantageously, the carrier 22 remains substantially horizontal during the installation process whereby the component parts 66 are retained on their respective part receivers 72 and remain oriented in position for installation.

[0043] While component parts 66 are in registry with part reception sites 90 , switch 76 , shown in FIG. 1 , can be actuated to at least partially discontinue the flow of air from part receivers 72 to vacuum source 74 , thereby releasing component parts 66 from part receivers 72 . Before part receivers 72 are removed from component parts 66 , component part carrier 22 can be shifted downward to force component parts 66 further into part reception sites 90 , thereby forming a snug fit between component parts 66 and part reception sites 90 so that component parts 66 maintain registry with part reception sites 90 during movement of platform 88 . The component part carrier can then be shifted to remove part receivers 72 from component parts 66 , thereby leaving component parts 66 disposed within part reception sites 90 . Component part carrier 22 can then be removed from the interior of vehicle body 34 to a retracted position for loading a new set of component parts 66 .

[0044] As shown in FIG. 2 , during the above-described installation process, vehicle body 34 can be traveling along an assembly line via assembly line track 32 and suspension device 36 . Carriage 26 can be translated in a direction corresponding to the direction of travel of vehicle body 34 along the assembly line, thereby allowing multiple component parts to be simultaneously installed in platform 88 while platform 88 is in continuous motion.

[0045] From the foregoing, it will be seen that this invention is well adapted to attain the objects herein above set forth, together with other advantages which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

[0046] Since many possible embodiments may be made of the invention without departing from the scope hereto, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrated and not in a limiting sense.