Patent Application
20140318421
The manufacturing and assembly process for automotive vehicles requires workers to both inspect and handle various parts. Some sheet metal parts, including door panels, roof panels, fenders, decklids, and other body panels can be heavy, large, or unwieldy, making the body panels difficult to position on unload tables in a manner that is both suitable for inspection and ergonomically acceptable for storage and installation handling of the body panels.
An apparatus and method for assisting workers in unloading panels in the vehicle manufacturing process.
In one implementation, a panel unload table apparatus is disclosed. The apparatus includes a table top; a table flap extending from the table top having a first position and a second position; and a panel fixture rotatable about a pivot axis and having: a stowed position substantially parallel to the table top; a load position substantially coplanar with the table top; and an unload position wherein the unload position is spaced angularly between the load position and the second position of the table flap.
In another implementation, a method for unloading a panel is disclosed. The method includes receiving the panel on a table top wherein the panel is positioned on the table top to allow a worker to make an external surface inspection; rotating a table flap extending from the table top from a first position to a second position to allow a worker access to a panel fixture in a stowed position; moving the panel fixture from the stowed position to a load position; receiving the panel on the panel fixture wherein the panel is positioned on the panel fixture to engage a load sensor; and in response to the load sensor sensing the panel on the panel fixture, rotating the panel fixture from the load position to an unload position.
In another implementation, a method for unloading a panel is disclosed. The method includes receiving the panel on a table top wherein the panel is positioned on the table top to allow a worker to make an external surface inspection; rotating a table flap extending from the table top from a first position substantially coplanar with the table top to a second position substantially perpendicular to the table top to allow a worker access to a panel fixture in a stowed position substantially parallel to the table top; moving the panel fixture from the stowed position to a load position substantially coplanar with the table top; receiving the panel on the panel fixture wherein the panel is positioned on the panel fixture to engage a load sensor; and in response to the load sensor sensing the panel on the panel fixture, rotating the panel fixture from the load position to an unload position spaced angularly between the load position and the second position of the table flap.
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
A panel unload table and methods for unloading panels using the panel unload table are described here. The panel unload table includes a table flap extending from and rotatably coupled to a table top. The panel unload table also includes a panel fixture stowed below the table top which can be extended and raised into a load position substantially coplanar with the table top when the table flap is in a folded position. The panel fixture includes a load sensor and rotary actuator which can rotate the panel, such as a door panel, fender panel, decklid, or other body panel, from the table top to a substantially vertical position to assist a worker in unloading the panel from the panel unload table in an ergonomic position.
The table flap 102 can also have a second position, such as the folded position shown in
For example, one or more pairs of slide rails 106 can be disposed on the lower surface of the table top 104. Additionally, a panel fixture 108 can be slidably disposed between a pair of slide rails 106. Each pair of slide rails 106 can store a panel fixture 108 fixture in a stowed position with the stowed position being substantially parallel to the table top 104 and at the same time below the lower surface of the table top 104. Each panel fixture 108 in its stowed position can be accessed by a worker when the table flap 102 is in the second, folded position.
A worker can move each panel fixture 108 from the stowed position as shown in
The panel unload table 100 can also include a table base 202. The table top 104 can be rotatably coupled to the table base 202 to allow adjustments in the inclination or the height of the table top 104. For example, the table top 104 can be a tilt-table top which is raised and lowered along the path of an arc to change the position and inclination of the table top 104 in respect to the table base 202. Allowing for various positions of the table top 104 can assist workers in sliding body panels along the table top to the panel fixtures 108 and account for the different physical characteristics between different workers, e.g., different heights or strengths.
The panel fixture 108 can also include a load sensor 300 and a rotary actuator 302. Once a body panel has been moved from the table top 104 to the panel fixture 108 in the load position, the load sensor 300, for example, a pneumatic switch or other sensor capable of recognizing the presence of a body panel, can send a signal to the rotary actuator 302 to rotate the panel fixture 108 about the pivot axis A-A. The rotary actuator 302 can cause the panel fixture 108 to move the body panel from the load position to an unload position. The panel fixtures 108 are shown in the unload position (without body panels in place) in
The stowed position of the panel fixtures 108 can be substantially parallel to the table top 104. Each panel fixture 108 can be slidably disposed between a pair of slide rails 106, with the slide rails 106 being disposed on a lower surface of the table top 104. After the table flap 102 has been rotated from the first position to the second position, the panel fixtures 108 can be moved from the stowed position to a load position. As shown in
The next step in the example method of unloading the door panels 500 includes receiving the door panels 500 on the panel fixtures 108 with the door panels 500 being positioned on the panel fixtures 108 in such a manner as to engage a load sensor 300. As described above, the load sensor 300 can be a pneumatic switch or any other sensor capable of recognizing the presence or weight of a door panel 500. Each door panel 500 can be positioned on a panel fixture 108 by a worker sliding the door panel 500 along the surface of the table top 104 and along the surface of the panel fixture 108 until the door panel engages one or more stop surfaces 200 at the end of the panel fixture 108. The table top 104 can also be rotatably coupled to the table base 202 so that the height of the table top 104 can be adjusted to positions suitable for a plurality of workers having varying physical characteristics.
By using the panel fixtures 108 to position the door panels 500 in the unload position, a worker who loads the panels onto the finished part pallets is able to grasp the door panels 500 without bending over the table and without raising his or her arms above the shoulder level, improving the ergonomics of the operation. Without the panel fixtures 108, the worker would be required to bend over the table, and pivot the heavy door panels 500 from the near horizontal surface of the table top 104 to a vertical position in order to unload the door panels 500 from the panel unload table 100. The improvement in ergonomic score using the panel fixtures 108 is over fifty percent when compared to the method of the worker bending over the table and pivoting the door panels 500 into an installation or storage position.
Another benefit of the panel unload table 100 design is the flexibility of using the panel unload table 100 as a traditional tilt-top table with a large table top 104 surface for inspection or storage purposes. The panel fixtures 108 can also be designed to return to the load position after the weight of a body panel has been removed from the panel fixture 108. This return can be based on the load sensor 300 sending a signal to the rotary actuator 302 to move the panel fixture 108 from the unload position back to the load position.
The foregoing description relates to what are presently considered to be the most practical embodiments. It is to be understood, however, that the disclosure is not to be limited to these 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.
