Automated Exterior Vehicle Assembly Using Global Datums

Abstract

To provide an automated system and method for assembling exterior vehicle parts to a vehicle assembly structure.SOLUTION: A system utilizes an automated assembly cell with fixtures corresponding to each exterior vehicle part and references a global datum for precise alignment. Exterior vehicle parts are secured to fixtures using vacuum clamps or other means, and a structural adhesive is applied to either the part or a part-receiving location on the vehicle assembly structure. The parts are then moved into their nominal positions relative to the global datum, thereby compressing the adhesive and completing the installation. The method improves assembly efficiency by compensating for substructure irregularities with an engineered adhesive gap and allows for continued assembly during adhesive curing through tacking operations. This technology streamlines the vehicle assembly process, enhances quality, and increases production rates by reducing manual labor and potential for error.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to automated assembly techniques, and more particularly to the automated attachment and alignment of exterior vehicle parts and components using adhesives and datum reference systems within the manufacturing process. [Background technology]

[0002] Traditional vehicle assembly methods often involve building a vehicle body by welding stamped panels. After the body is constructed, it is passed through various systems, such as e-coat and paint systems, to provide corrosion resistance and the desired aesthetic finish. The painted body is then moved to a general assembly (GA) plant, where interior and exterior components are assembled. This process can be inefficient in material handling and transportation, as the entire weight and footprint of the vehicle must be moved to assemble smaller components. Additionally, this method can limit the ability to automate many manufacturing processes, as it is difficult and expensive to locate and acquire assembly data at the complete vehicle level.

[0003] Assembly of exterior vehicle components has traditionally involved a series of manual and semi-automated processes. These processes often require precise alignment and attachment of panels and parts to the vehicle frame to ensure proper fit, finish, and function. The complexity of these tasks can lead to challenges in maintaining consistent quality and efficiency throughout the production line. Manufacturers have explored various ways to streamline these tasks, with the goal of reducing the time and labor associated with vehicle assembly while maintaining high standards of quality and craftsmanship.

[0004] The integration of automation into assembly lines has been a focus of the industry in an effort to increase production speeds and reduce the possibility of human error. Despite advances in automation technology, the assembly of exterior vehicle components remains an area with unique challenges due to the variety of materials used, the need for precise alignment, and the requirement for durable, reliable attachment methods that can withstand the rigors of vehicle operation.

[0005] One of the key issues with traditional assembly methods is the potential for compounding errors. As each component is added to the vehicle, slight misalignments or variations can add up, leading to larger discrepancies as the assembly process continues. This can be particularly problematic when it comes to ensuring uniform gaps and flushness between exterior panels, which is important for both aesthetic and aerodynamic performance. Summary of the Invention

[0006] In attempting to address at least some of the above challenges, examples of the present disclosure utilize a global datum within an automated assembly cell. In some examples, the global datum is a singular or unique global datum. This singular global datum serves as a universal reference point for the positioning and installation of all exterior parts. Using this method, each exterior panel is calibrated to a single datum, ensuring that every part is positioned in its nominal position relative to its neighbors. In some examples, this approach effectively decouples the assembly process, allowing for precise placement of exterior components without being affected by the tolerances of the underlying structure. The global datum ensures that external fits are consistently accurate, reducing the chance of error accumulation throughout the assembly process. The use of a global datum also facilitates automation of the assembly process, as robotic systems can reference this single point for all operations, leading to increased efficiency and repeatability.

[0007] Thus, some examples seek to improve the way exterior vehicle components are assembled during the manufacturing process. The technology addresses the challenge of aligning and installing parts such as doors, panels, and trim with high precision and consistency. Some examples aim to streamline the vehicle assembly process, improving the quality of the final product and increasing the efficiency of the production line.

[0008] In the described example, the modular vehicle architecture allows the vehicle to be assembled in sections that are then joined in a final assembly operation. This approach eliminates the traditional need to weld stamped panels and apply secondary coatings or paint at the complete vehicle assembly level. Instead, the vehicle can be constructed with components that have pre-applied metal surface treatments, such as e-coating and painting.

[0009] Some described examples utilize automated assembly cells in which each part to be installed has a corresponding fixture. These fixtures are designed to hold the part in place, typically using vacuum clamps and / or other clamping means, while the structural adhesive is applied. The part is then moved to a nominal position (described further below), the structural adhesive is compressed, and the installation of the exterior part is completed. This method can help ensure that the exterior parts are properly aligned and securely attached.

[0010] One component of this technology is the use of a single global datum within an automated assembly cell. This global datum serves as a universal reference point for all parts, ensuring that each part is installed in the correct position relative to the others. An exemplary system seeks to enable the assembly of vehicles with parts that fit together well every time, regardless of irregularities or variations in the underlying structure.

[0011] The disclosed example also basics structure (It incorporates an engineered bonding gap that can compensate for irregularities in the substructure, effectively decoupling the tolerances of the substructure from the installed part position. This bonding gap provides flexibility between bonded parts with high repeatability, accommodating different heating or material properties without the need for additional components.

[0012] In some instances, different structural adhesive chemistries can be used to tailor the time it takes for the adhesive to set or complete the assembly process, as well as the final mechanical properties of the adhesive. Additionally, tack solutions can be used simultaneously with the structural adhesive to allow for immediate, continuous assembly while the primary adhesive cures. Examples of tack solutions include self-piercing datums and fast-curing hot melt adhesives.

[0013] In some examples, self-piercing datums use raised datum pins that can be pressed into a piercing medium, such as conforming foam or other substrate, during installation to secure the exterior part in place before the structural adhesive cures. In some examples, these datum pins have additional profile features to ensure a secure hold. Datum pins may also be heated before installation to expand the range of applicable substrate materials.

[0014] In some instances, hot melt adhesives are applied locally, either simultaneously with the primary adhesive or in rapid succession. They cool faster than the primary adhesive cures, allowing for accelerated takt time. This means that the next vehicle can move through the assembly cell more quickly (reducing takt time), thereby increasing overall production speed.

[0015] Due to the tight tolerances on exterior vehicle components, such as body panels, that are installed using this technology, the installation of additional components can be automated without the need to dimensionally assess each vehicle. This repeatable tight tolerance can further increase the efficiency of the vehicle assembly process.

[0016] Some examples also address serviceability issues. Attaching exterior components using adhesives and fasteners reduces or eliminates the need for traditional fasteners and clips. This can simplify the process of repairing or replacing components because there are fewer components to remove and reinstall.

[0017] In summary, the described examples seek to provide a method for assembling exterior vehicle components that is more efficient than conventional methods and produces a higher quality product. By using an automated assembly cell with global datums and advanced bonding technology, the method seeks to enable accurate and consistent placement of parts, reduce the possibility of errors, and improve the overall efficiency of the vehicle assembly process. [Brief explanation of the drawings]

[0018] Throughout the drawings, reference numbers may be reused to indicate correspondence between referenced elements. The drawings are provided to illustrate examples of the subject matter described herein and not to limit its scope.

[0019] [Figure 1] 1 illustrates an exemplary vehicle assembly structure and associated components, according to some examples.

[0020] [Figure 2] 1 provides an illustration of exemplary components of a system for attaching exterior vehicle parts to a vehicle assembly structure, including a fastener corresponding to the exterior vehicle part, according to some examples.

[0021] [Figure 3A] 1 illustrates some disadvantageous aspects and / or complications of conventional exterior vehicle component assembly techniques with several conventional examples.

[0022] [Figure 3B]1 illustrates (for comparison) aspects of a simplified process for bonding exterior vehicle components to a vehicle assembly structure using an automated assembly cell and structural adhesives, according to some current examples.

[0023] [Figure 4A] 1A-1C show a vehicle that is nearly complete except for exterior panels, according to some examples, and show a vehicle assembly structure ready for the addition of exterior vehicle parts.

[0024] [Figure 4B] 1 illustrates an automated assembly cell having an array of exterior vehicle parts and vehicle glass positioned adjacent to a robot with a global datum for alignment, according to some examples.

[0025] [Figure 4C] 10 illustrates movement of exterior vehicle components to their nominal positions referenced to a global datum, according to several examples, and compresses the structural adhesive to bond the components to the vehicle assembly structure.

[0026] [Figure 4D-E] FIG. 4D illustrates a vehicle with assembled exterior vehicle parts exiting an automated assembly cell, according to some examples.

[0027] FIG. 4E illustrates the process of making the exterior-facing electrical connections and applying trim closeouts, according to some examples.

[0028] [Figure 4F] 10 illustrates the application of the Aeroshield to complete the assembly stage of a vehicle, according to some examples.

[0029] [Figure 5A] FIG. 1 is a diagram depicting a series of automated assembly cells in a vehicle assembly line, detailing exemplary stages of pre-assembly, exterior vehicle part installation, and downstream exterior vehicle part installation, according to some examples. [Figure 5B]FIG. 1 is a diagram depicting a series of automated assembly cells in a vehicle assembly line, detailing exemplary stages of pre-assembly, exterior vehicle part installation, and downstream exterior vehicle part installation, according to some examples. [Figure 5C] FIG. 1 is a diagram depicting a series of automated assembly cells in a vehicle assembly line, detailing exemplary stages of pre-assembly, exterior vehicle part installation, and downstream exterior vehicle part installation, according to some examples.

[0030] [Figure 6] 1 illustrates the stress and displacement of an exterior vehicle part, specifically a plastic door panel, when adhesively bonded to an aluminum frame using various thicknesses of urethane structural adhesive, according to several examples.

[0031] [Figures 7A-E] 10A-10C illustrate exemplary tacking operations in an assembly process, including the use of datum pins and a tacking applicator to secure exterior vehicle parts in their nominal positions before a structural adhesive cures, according to some examples.

[0032] [Figure 8A] 1A-1C illustrate various views of an exemplary datum pin in the form of a raised datum pin, according to some examples. [Figure 8B] 1A-1C illustrate various views of an exemplary datum pin in the form of a raised datum pin, according to some examples. [Figure 8C] 1A-1C illustrate various views of an exemplary datum pin in the form of a raised datum pin, according to some examples.

[0033] [Figure 9] 10 illustrates a further exemplary tacking operation in an assembly process, including the use of datum pins to secure exterior vehicle parts in their nominal positions before the structural adhesive cures, according to some examples.

[0034] [Figure 10A]10A-10C illustrate various stages of a framing station of an automated assembly cell, including application of structural adhesive, assembly of exterior vehicle parts, and clipping of interlocking panels, according to some examples. [Figure 10B] 10A-10C illustrate various stages of a framing station of an automated assembly cell, including application of structural adhesive, assembly of exterior vehicle parts, and clipping of interlocking panels, according to some examples. [Figure 10C] 10A-10C illustrate various stages of a framing station of an automated assembly cell, including application of structural adhesive, assembly of exterior vehicle parts, and clipping of interlocking panels, according to some examples. [Figure 10D] 10A-10C illustrate various stages of a framing station of an automated assembly cell, including application of structural adhesive, assembly of exterior vehicle parts, and clipping of interlocking panels, according to some examples.

[0035] [Figure 11] A comparison table is provided showing comparative values ​​and specifications of the disclosed method and conventional method of attaching exterior vehicle parts to a vehicle assembly structure according to several examples. DETAILED DESCRIPTION OF THE INVENTION

[0036] Some examples provide an automated installation system for vehicle exteriors in which multiple exterior vehicle components, such as panels and glass, are positioned and installed within a vehicle assembly structure with reference to a single or unique global datum. Each installed component has a corresponding fixture within the automated assembly cell. The components are secured to their respective fixtures by vacuum clamps and / or other clamping means.

[0037] Structural adhesive is dispensed onto either the clamped parts or onto part-receiving locations or areas on the vehicle assembly structure. Using a global datum as a reference, the parts are moved to their respective nominal positions, compressing the structural adhesive to bond the parts to the vehicle assembly structure and complete the part installation. In some instances, the term "nominal position" refers to the intended or designed location of a part within a larger assembly or system. In the context of manufacturing and engineering, this is the precise location where a component should be placed according to design specifications. This location is determined by the design of the product (e.g., vehicle) and is used as a reference point that is evaluated against the global datum during the assembly process to ensure each part is properly installed.

[0038] In some instances, when a part is in its nominal position, it means that it is precisely aligned and oriented according to specifications (e.g., as planned by a vehicle designer or engineer). This precise positioning helps ensure that the part functions as intended and that the overall assembly has the correct form, fit, and function. Because deviations from the nominal position can lead to issues such as improper fit, panel gaps, interference with other components, or reduced structural integrity, ensuring repeatable assembly of exterior vehicle parts in the nominal position can be important to maintain the quality and performance of the finished vehicle.

[0039] In some instances, the engineered adhesive gap may be: basics It compensates for structural irregularities and decouples base structural tolerances from installed part location. This assembly structure allows for highly repeatable, as-designed gap and flush specifications for all parts. Additionally, the adhesive gap provides flexibility between bonded parts, compensating for inherently different heating or material properties without additional components. Different primary adhesive chemistries can be used to adjust takt time and final mechanical properties.

[0040] A tack solution can be used simultaneously with the application of the primary adhesive to allow for immediate, continuous assembly while the primary adhesive cures. The tack solution can include a self-piercing datum and a hot melt adhesive. In some examples, the self-piercing datum pin includes a raised datum pin for pressing into a conforming foam or other substrate during installation to secure the part in its nominal position before the final adhesive cures. In some examples, the pin has additional profile features to ensure a secure hold. The piercing pin may also be heated before installation to expand the range of applicable substrate materials. In some examples, the hot melt adhesive is applied locally simultaneously or in rapid succession with the structural adhesive. The hot melt adhesive cools faster than the primary adhesive cures, allowing for accelerated takt time.

[0041] Additional components can be connected to downstream auto-adhesive panels. Due to the tight tolerances on such panels, installation of additional components can be automated without the need to dimensionally assess each vehicle.

[0042] FIG. 1 shows a pictorial diagram of an exemplary vehicle assembly structure 102. The vehicle assembly structure 102 may include one or more body frames 214, such as, for example, door inners or hood inners. Further examples of body frames 214 forming part of the vehicle assembly structure 102 are provided further below. According to some examples described herein, the one or more body frames 214 may be pre-assembled to the vehicle assembly structure 102. In some examples, as described further below, one or more exterior vehicle parts 104 are assembled to the vehicle assembly structure 102. Exemplary exterior vehicle parts 104 may include, for example, quarter panels 528 or glass 404. The one or more exterior vehicle parts 104 may be assembled to the one or more body frames 214 of the vehicle assembly structure 102.

[0043] 2 shows a diagram of some example components of a system for attaching an exterior vehicle part to a vehicle assembly structure 216. The example components include a fixture 202. The fixture 202 is shaped and configured (for example) as shown so that at least one surface or dimension precisely corresponds to an exterior vehicle part, such as the illustrated exterior vehicle part 104 (here, an exterior door panel, also known as a door outer). The exterior vehicle part 104 is attached to a body frame 214 (in this case, a door frame, also known as a door closure, or an inner door) of the vehicle assembly structure 102. In some examples, the body frame 214 is pre-assembled to the vehicle assembly structure 102.

[0044] The exterior vehicle parts 104 are secured to their respective fixtures 202 using other clamping means 206, such as, for example, vacuum clamps 208, or mechanical clamps attached to the end of a hydraulic ram (not shown), or magnets on a robotic arm. Other methods and / or means for securing the exterior vehicle parts 104 to the fixtures 202 are possible. In some examples, each of the exterior vehicle parts 104 of a vehicle 406 (e.g., FIG. 4A below) may be provided with a respective fixture 202 shaped and configured to securely receive the associated exterior vehicle part 104 in an exemplary manner for attaching the exterior vehicle part to a vehicle assembly structure.

[0045] In some examples, structural adhesive 210 is applied to a fixed exterior vehicle part 104 or part receiving location 306 on fixture 202 (see, e.g., FIG. 3B below). Fixed exterior vehicle part 104 (door panel) can be moved by positioning mechanism 212 to a respective nominal position (e.g., nominal position 204 positioned relative to the door panel as shown) relative to a single or unique global datum (see, e.g., global datum 402 in FIG. 4B ) to compress structural adhesive 210 and complete installation of exterior vehicle part 104 to vehicle assembly structure 102, or in this case, body frame 214 (door frame).

[0046] In some examples, the chemistry of the structural adhesive 210 is selected to adjust the vehicle assembly takt time (the time it takes to complete an assembly step in an automated assembly cell or to move between automated assembly cells) or to adjust the final mechanical properties or cure time of the adhesive bond between the exterior vehicle component 104 and the vehicle assembly structure 102 or body frame 214. In some examples, the structural adhesive 210 comprises a urethane or polyurethane material.

[0047] In some examples, to compensate for structural or other irregularities, a bonding gap 222 is provided in the bond path of the exterior vehicle component 104 to the body frame 214. The bonding gap 222 may be ... basics Irregularities may exist in one or more locations of the structure (e.g., body frame 214). In some examples, the adhesive gap 222 corresponds to differences in thermal or material properties between the exterior vehicle component 104 and the fastener 202, and / or between the bonded exterior vehicle component 104 and the vehicle assembly structure 102 or body frame 214. In some examples, for example, as shown, the adhesive gap 222 is located adjacent to the nominal location 204 of the exterior vehicle component 104 and / or body frame 214. Other locations for the adhesive gap 222 are also possible. In some examples, the adhesive gap 222 is located at or above the nominal location 204, or at least includes the nominal location 204 within the width of the adhesive gap 222 or bead of structural adhesive.

[0048] Thus, in a broad aspect, a method for attaching an exterior vehicle part to a vehicle assembly structure is provided. An exemplary method includes providing an automated assembly cell having one or more fixtures, each fixture corresponding to an exterior vehicle part, referencing a global datum for aligning the exterior vehicle part within the automated assembly cell, securing the exterior vehicle part to the respective fixture using a vacuum clamp or other clamping means, applying a structural adhesive to the secured exterior vehicle part or a part-receiving location on the vehicle assembly structure, and moving the secured exterior vehicle part to a respective nominal position relative to the global datum to compress the structural adhesive and complete installation of the exterior vehicle part to the vehicle assembly structure.

[0049] In some examples, the component receiving locations are included within or on a body frame of the vehicle assembly structure. In some examples, the exterior vehicle components are moved sequentially to their respective nominal positions relative to a global datum. In some examples, at least some of the exterior vehicle components are moved simultaneously or partially simultaneously to their respective nominal positions relative to a global datum. In some examples, the respective nominal positions are or correspond to intended or final positions of the exterior vehicle components within the vehicle assembly structure as determined by design specifications.

[0050] Some further examples are exterior vehicle parts, fixtures, or vehicle assembly structures. basics and providing an adhesive gap to compensate for structural irregularities. Some examples further include selecting the chemistry of the structural adhesive to adjust the vehicle assembly takt time or the final mechanical properties of the adhesive bond between the exterior vehicle component and the vehicle assembly structure or body frame. In some examples, the structural adhesive includes a urethane or polyurethane. In some examples, the adhesive gap corresponds to differences in thermal or material properties between the bonded exterior vehicle component and the vehicle assembly structure, or between the exterior vehicle component and the body frame. Other technical features will be readily apparent to those skilled in the art from the following drawings, description, and claims.

[0051] FIG. 3A illustrates certain challenges and / or complexities of conventional exterior vehicle component assembly techniques. For example, an exterior panel (e.g., side A) is supplied and enters a separate panel assembly line. The exterior panel typically requires one or more intra-panel attachments to an interior panel. For this purpose, the interior panel is provided with a clip mechanism. A panel-side clip and a body-side clip (e.g., as shown) are required, and each clip must be installed separately in a laborious and / or time-intensive manner. The assembled interior and exterior panels are then attached to a body closure or frame, as shown. These exterior component assembly operations can require many relatively complex steps.

[0052] Conversely, as generally shown in FIG. 3B , some exemplary methods of the present disclosure include a more efficient process for assembling exterior vehicle parts. In some examples, exterior vehicle parts 104 are bonded to a vehicle assembly structure 102 or a body frame. The vehicle assembly structure 102 may include a pre-assembled body frame 214 to which the exterior vehicle parts 104 are bonded. The act of bonding the exterior vehicle parts 104 to the vehicle assembly structure 102 (or body frame 214) may include dispensing structural adhesive 210 onto the exterior vehicle parts 104 at part receiving locations 306 or within an automated assembly cell 304 using a dispensing mechanism 302 (as shown).

[0053] In Figure 4A, a substantially complete vehicle 406 is shown, excluding exterior panels. In this form, the vehicle includes or is comprised of a vehicle assembly structure 102. The vehicle assembly structure 102, as shown, may include one or more body frames 214. In some examples, as shown in Figure 4B, the one or more body frames 214 are pre-assembled to the vehicle assembly structure 102 or form at least a portion of the vehicle assembly structure 102 before the vehicle assembly structure 102 moves to an exterior component fixture station or automated assembly cell 304.

[0054] 4B, an array of exterior vehicle parts 104 and / or panes of vehicle glazing 404 are shown adjacent to and within the reach of a robot of the automated assembly cell 304. The automated assembly cell 304 includes a global datum 402 for aligning the exterior vehicle parts 104 and / or panes of glass 404 within the automated assembly cell 304. The global datum 402 may be defined by a structure of the automated assembly cell 304, by a reference mechanism, or by a virtual point or structure relative to the automated assembly cell 304.

[0055] As described above, structural adhesive 210 is dispensed onto either the vacuum-clamped exterior vehicle components 104 or component-receiving locations 306 or areas on the vehicle assembly structure 102. In FIG. 4C , with reference to the global datum 402, each exterior vehicle component 104 is moved to its respective nominal position in the manner described above, thereby compressing the structural adhesive 210 to bond the exterior vehicle component 104 to the vehicle assembly structure 102 (or to the body frame 214 or closure, in some examples) and complete the installation of the component thereon.

[0056] In some examples, the exterior vehicle parts 104 are moved sequentially to their respective nominal positions relative to the global datum 402. In some examples, at least some of the exterior vehicle parts 104 are moved simultaneously or partially simultaneously to their respective nominal positions relative to the global datum 402.

[0057] In some instances, the term "nominal position" refers to the intended or designed location of a part within a larger assembly or system. In manufacturing and engineering contexts, this is the exact location where a component should be placed according to design specifications. This location is determined by the design of a product (e.g., a vehicle) and is used as a reference point that is evaluated against a global datum during the assembly process to ensure each part is installed correctly. In some instances, when a part is in its nominal position, it means that it is precisely aligned and oriented according to specifications, as planned by, for example, a vehicle designer or engineer. This precise placement helps ensure that the part functions as intended and that the overall assembly has the correct shape, fit, and function. The nominal position can be important to maintaining the quality and performance of the finished product, as deviations from this position can lead to issues such as improper fit, interference with other components, or reduced structural integrity.

[0058] In some examples, an engineered adhesive gap (such as adhesive gap 222) is used in one or more of the partial fixation operations of FIG. basics It compensates for structural irregularities, thereby decoupling basic structural tolerances from installed part location. In some instances, this assembly structure allows for highly repeatable, as-designed gap and flush specifications for all parts. Additionally, the adhesive gap provides flexibility between bonded parts, compensating for inherently different heating or material properties without additional components. Different primary adhesive chemistries can be used to adjust takt time and final mechanical properties.

[0059] In Figure 4D, a vehicle 406 including a vehicle assembly structure 102 with exterior vehicle parts 104 attached leaves the automated assembly cell 304. In Figure 4E, in some examples, one or more exterior-facing electrical connections 408 are formed and one or more trim closeouts are applied. In Figure 4F, in some examples, one or more aeroshiels 410 are applied to complete the assembly (or at least the assembly stage) of the vehicle 406.

[0060] 5A-5C, one or more automated assembly cells 304 may be provided in a vehicle assembly line that includes a system for attaching exterior vehicle parts to a vehicle assembly structure 216. FIG. 5A may include a pre-assembly stage that is performed manually within the automated assembly cell 304 or outside of the automated assembly cell 304, where an example body frame 214 is pre-assembled to the vehicle assembly structure 102. The example body frame 214 may include one or more of a body frame 214 (such as a door inner or door closure), a wheel liner 518, a hood inner 520, a trunk inner 522, and a front end carrier 524.

[0061] 5B , the further (or first) automated assembly cell 304 installs exterior vehicle parts 104 onto the vehicle assembly structure 102, and more specifically onto one or more of the body frames 214 of the vehicle assembly structure 102. Exemplary exterior vehicle parts 104 may include panels of vehicle glass 404, quarter panels 528, a rear fascia 530, a shutface 532 (or door sills), a cant rail 534, a windshield 536, and a roof 538.

[0062] 5C , a further (or second) automated assembly cell 304 installs further or downstream exterior vehicle parts 104 onto the vehicle assembly structure 102 and / or its body frame 214. Exemplary downstream exterior vehicle parts 104 may include one or more of a front fascia 540, a hood outer 542, a tailgate outer 544, a door skin 546, and a rocker 548.

[0063] During post-assembly stages, one or more electrical wiring or harness connections (such as exterior-facing electrical connections 408) can be made, wiper blades can be attached, and one or more aero shields 410 can be installed. Other post-assembly stages or operations are also possible.

[0064] 6 shows example stress and displacement diagrams for an exterior vehicle part, in this case a plastic door panel, adhesively bonded to an aluminum frame (as the exemplary body frame 214 of the vehicle assembly structure 102) using various exemplary thicknesses of urethane structural adhesive 210. The door panel was bonded to the aluminum frame using the automated assembly cell 304 and the fasteners and structural adhesive as further described above.

[0065] The structural adhesive 210 applied to bond the door panel to the aluminum frame was dispensed at various test thicknesses of 2 millimeters (mm), 4 mm, 6 mm, and 8 mm, resulting in exemplary door panel stresses (MPa) as shown in respective stress value distribution charts 606, and displacements or deformations (mm) as shown in respective displacement value distribution charts 614. The stress and displacement distribution values ​​are shown in respective stress scoring bars 610 and displacement scoring bars 612.

[0066] Using the methods of the present disclosure, it can be seen that there is little discernible displacement (or deformation) of the door panel (as an exemplary exterior vehicle part 104) when assembled to the aluminum frame (as an exemplary part of the vehicle assembly structure 102). The stresses applied are relatively gentle. This lack of deformation and stress can be an important factor in facilitating consistent and repeatable accuracy in the placement of panels and exterior vehicle parts on the vehicle.

[0067] 7A-7E illustrate exemplary tacking operations in an assembly process, including the use of datum pins and a tacking applicator to secure exterior vehicle components in their nominal positions before the structural adhesive cures, according to some examples.

[0068] Examples of tack solutions include self-piercing datums and / or fast-curing hot-melt adhesives. In some instances, self-piercing datums use raised datum pins that can be pressed into a piercing medium, such as conforming foam or other substrate, during installation to secure the exterior part in place before the structural adhesive cures. In some instances, these datum pins have additional profile features to ensure a secure hold. Datum pins may also be heated prior to installation to expand the range of applicable substrate materials.

[0069] As shown in the diagrams of FIGS. 7A-7E, one or more datum pins 704 are provided at fixed locations on the body frame 214, such as a door inner or door closure. For example, as seen more clearly in the enlarged views of FIGS. 8A-8C, the datum pin 704 may be provided in the form of a raised datum pin 710. Other types of datum pins are also possible, such as the self-piercing datum pin 902 shown in FIG. 9. The raised datum pin 710 and / or the self-piercing datum pin 902 on the body frame 214 can engage with the exterior vehicle component 104, or vice versa. In some examples, the raised datum pin 710 and / or the self-piercing datum pin 902 provided on the body frame 214 may be received in a piercing medium 714 provided on the exterior vehicle component 104 (such as the door panel in FIG. 7A) to allow continued assembly of the vehicle assembly structure until the structural adhesive cures. Other tacking configurations are also possible. In some examples, the tacking operation includes applying one or more datum pins to the exterior vehicle part or vehicle assembly structure to secure the tacked exterior vehicle part in its nominal position before the structural adhesive cures.

[0070] 9 , one or more self-piercing datum pins 902 provided by a tack applicator on the door inner (as the exemplary body frame 214) are each received in a corresponding piercing medium 714, such as conforming foam, provided on the door outer (as the exemplary exterior vehicle part 104), to allow for continued assembly of the vehicle assembly structure 102 until the structural adhesive cures. By allowing for continued assembly of the vehicle assembly structure 102 until the structural adhesive cures, the takt time of the vehicle assembly structure 102 moving within or between adjacent automated assembly cells 304 in a vehicle assembly line can be reduced, for example.

[0071] 10A, a partially assembled vehicle 1002 (including vehicle assembly structure 102) enters a framing station of automated assembly cell 304 and is supported from below by datum structures, one of which includes a global datum, such as a singular or reference global datum 402 of the type described above.

[0072] In Figure 10B, one or more arms of the robot 1004 apply urethane as structural adhesive 210, as needed, to one or more exterior vehicle components 104, such as the illustrated vehicle glass 404. In Figure 10C, additional exterior vehicle components 104 are assembled (glued) to the vehicle assembly structure 102 of the vehicle 1002 using one or more respective fasteners 202 and structural adhesive 210, as described above. The exterior vehicle components 104 are positioned in nominal positions, in some examples, utilizing self-piercing datums.

[0073] In some examples, the structural adhesive 210 、 Examples include Betaseal 15709. Exemplary applications of the structural adhesive 210 are approximately 80 g / m in an 8 mm to 16 mm bead of structural adhesive 210. In some examples, up to 60 meters (total length or perimeter) of structural adhesive 210 is applied to one or more exterior vehicle components 104, which corresponds to approximately 4.8 kg of structural adhesive 210. to Equivalent.

[0074] In FIG. 10D, in some examples, interlocking panels between assembled exterior vehicle parts 104 are clipped together as shown by clipping 1014 before exiting the framing station of the automated assembly cell 304.

[0075] FIG. 11 shows a comparison table 1102 illustrating comparative values ​​and specifications of an exemplary method of attaching exterior vehicle parts to a vehicle assembly structure of the present disclosure compared to other conventional methods referenced in the comparison table 1102 .

[0076] In some instances, automated exterior part assembly systems with fixtures increase maintainability by reducing the number of parts and fasteners required for exterior panel installation. This simplification of the assembly process not only reduces labor costs, but also makes the vehicle easier to maintain because there are fewer components to remove and reinstall. Additionally, the system offers noise, vibration, and harshness (NVH) improvements by eliminating separate joining parts such as clips, pins, and fasteners. This can result in a quieter, more comfortable ride for vehicle occupants.

[0077] Some examples herein are highly compatible with automation, allowing for the automation of the exterior assembly process. This compatibility with automation technology contributes to reducing takt time and labor requirements, thereby improving the overall efficiency of the vehicle assembly process. In some examples, the craftsmanship of the finished product is also maintained or improved, as the system allows for repeatable placement of the exterior, thus helping to ensure each vehicle meets high-quality standards.

[0078] In some instances, the disclosed technology may find utility beyond the field of automotive assembly, extending its applicability to the assembly of various subsystems within the automotive industry, as well as other products requiring assembly processes. A notable advantage of the disclosed technology is the possibility of achieving a significant, if not complete, reduction in the number of components typically used in exterior panel fasteners and clip components. This reduction represents a significant step toward achieving full exterior automation, which can contribute to a reduction in both takt time and labor required for assembly.

[0079] For illustrative purposes, consider the assembly of a Cybertruck roof applique, which traditionally utilizes five mounting brackets, each with three parts. These fastening components account for substantially 65% ​​of the total part count for this particular assembly. By implementing the disclosed technology and eliminating the fastening mechanisms, the total part count can be dramatically reduced from 23 to only 8 components.

[0080] The competitive advantages offered by some examples of the disclosed technology can be multifaceted. First, an automated exterior architecture with fixtures ensures that exterior components are placed in their nominal positions with each assembly cycle. This precision facilitates achieving tighter gap and flush targets, paving the way for eliminating the need for end-of-line refitting. Second, the technology reduces both part count and associated costs by eliminating the need for separate mating components such as clips, pins, and fasteners. Third, improved NVH and reliability are realized through the elimination of these separate mating components. Finally, an automated exterior installation system significantly accelerates vehicle-to-vehicle takt time and improves overall production efficiency compared to traditional manual assembly lines.

[0081] Example

[0082] Thus, some embodiments may include one or more of the following examples.

[0083] Example 1 A method for attaching exterior vehicle parts to a vehicle assembly structure, the method comprising: providing an automated assembly cell having one or more fixtures, each fixture corresponding to an exterior vehicle part; referencing a global datum for aligning the exterior vehicle parts within the automated assembly cell; securing the exterior vehicle parts to their respective fixtures using vacuum clamps or other clamping means; applying structural adhesive to the secured exterior vehicle parts or to part-receiving locations on the vehicle assembly structure; and moving the secured exterior vehicle parts to their respective nominal positions relative to the global datum to compress the structural adhesive and complete installation of the exterior vehicle parts to the vehicle assembly structure.

[0084] Example 2 The method of example 1, wherein the component receiving location is included in a body frame of the vehicle assembly structure.

[0085] Example 3 The method of example 1 or 2, wherein the exterior vehicle parts are continuously moved to their nominal positions relative to a global datum.

[0086] Example 4 The method of any one of Examples 1 or 2, wherein at least some of the exterior vehicle parts are simultaneously moved to their respective nominal positions relative to a global datum.

[0087] Example 5. The method of any one of Examples 1 to 4, wherein each nominal position is or corresponds to an intended or final position of an exterior vehicle component within a vehicle assembly configuration as determined by design specifications.

[0088] Example 6 Exterior vehicle parts, fixtures, or vehicle assembly structures basics 6. The method of any one of Examples 1 to 5, further comprising providing a bonding gap to compensate for irregularities in the structure.

[0089] Example 7 The method of Example 6, wherein the adhesive gap corresponds to a difference in thermal or material properties between the bonded exterior vehicle component and the vehicle assembly structure.

[0090] Example 8. The method of any one of Examples 1 to 7, further comprising selecting the chemistry of the structural adhesive to adjust the vehicle assembly takt time or the final mechanical properties of the adhesive bond between the exterior vehicle component and the vehicle assembly structure.

[0091] Example 9 The method of any one of Examples 1 to 8, wherein the structural adhesive comprises polyurethane.

[0092] Example 10. The method of any one of Examples 1 to 9, further comprising performing a tacking operation simultaneously with the application of the structural adhesive to allow for continued assembly of the vehicle assembly structure until the structural adhesive cures.

[0093] Example 11. The method of example 10, wherein the tacking operation includes applying one or more datum pins to the exterior vehicle part or vehicle assembly structure to secure the tacked exterior vehicle part in its nominal position before the structural adhesive cures.

[0094] Example 12. The method of example 11 or example 12, wherein the one or more datum pins include a self-piercing datum pin.

[0095] Example 13. The method of example 11 or 12, wherein the one or more datum pins include a raised datum pin for insertion into a piercing medium or other substrate to secure the tacked exterior vehicle part in its nominal position before the structural adhesive cures.

[0096] Example 14 The method of any one of Examples 11 to 13, wherein the one or more datum pins are heated prior to installation.

[0097] Example 15 The method of any one of Examples 10 to 14, wherein the tacking operation further comprises a hot melt adhesive applied simultaneously or sequentially with the structural adhesive.

[0098] Example 16 The method of Example 15, where the hot melt adhesive cures faster than the structural adhesive, facilitating accelerated takt time.

[0099] Example 17. The method of any one of Examples 1 to 16, further comprising connecting additional exterior vehicle parts to the vehicle assembly structure downstream in the assembly line to further complete assembly of the vehicle.

[0100] Example 18. The method of example 17, wherein the connection of the additional exterior vehicle component to the vehicle assembly structure is without dimensional evaluation of the assembled vehicle.

[0101] Example 19: A system for attaching exterior vehicle parts to a vehicle assembly structure, the system comprising: an automated assembly cell having a respective fixture for each exterior vehicle part; a global datum for aligning the exterior vehicle parts within the automated assembly cell; a clamping mechanism for holding the exterior vehicle parts in the respective fixtures using vacuum clamps or other clamping means; a dispensing mechanism for applying structural adhesive to the clamped exterior vehicle parts or to part-receiving locations on the vehicle assembly structure; and a positioning mechanism for moving the clamped exterior vehicle part to a nominal position relative to the global datum to compress the structural adhesive and complete installation of the clamped exterior vehicle part to the vehicle assembly structure.

[0102] Example 20. The system of example 19, wherein the clamped exterior vehicle part is continuously moved to a nominal position relative to a global datum.

[0103] Example 21 The system of example 19, wherein the clamped exterior vehicle part is moved to the nominal position simultaneously with another exterior vehicle part.

[0104] Example 22. The system of any one of Examples 19 to 21, wherein the nominal position is or corresponds to the intended or final position of the exterior vehicle component within the vehicle assembly structure as determined by design specifications.

[0105] Example 23 Exterior vehicle parts, fixtures, or vehicle assembly structures basics 23. The system of any one of Examples 19 to 22, configured to provide an adhesive gap to compensate for irregularities in the structure.

[0106] Example 24. The system of example 23, wherein the adhesive gap corresponds to a difference in thermal or material properties between the bonded exterior vehicle component and the vehicle assembly structure.

[0107] Example 25. The system of any one of Examples 19 to 24, further comprising a tacking applicator for performing a tacking operation simultaneously with application of the structural adhesive to allow for continued assembly of the vehicle assembly structure until the structural adhesive cures.

[0108] Example 26. The system of Example 25, wherein the tacking applicator is further configured to apply one or more self-piercing datums or hot melt adhesives to one or more of the exterior vehicle components.

[0109] In some examples, a method of assembling an exterior vehicle component to a vehicle assembly structure is provided, the method including isolating a panel gap from the tolerances of a body or closure assembly by utilizing a bond gap designed to absorb tolerance mismatches between the exterior vehicle component and the underlying structure, and compensating for differences in coefficient of thermal expansion (ΔCTE) between the exterior vehicle component and the underlying structure to maintain component integrity and conform under various temperature conditions.

[0110] In some examples, the vehicle assembly system includes means for improving serviceability by reducing the number of separate interface parts required for installation of exterior vehicle components, thereby simplifying the assembly and maintenance process, and means for improving the NVH characteristics of the vehicle by eliminating separate interface parts.

[0111] In some examples, a method is provided for assembling exterior vehicle components into a vehicle assembly structure, the method including implementing an assembly process that is compatible with automated techniques to reduce takt time and labor requirements, and ensuring repeatable placement of the exterior components to maintain or improve craftsmanship of the finished product.

[0112] It should be noted that the above description and figures, together with the examples described herein, merely illustrate the principles of the present subject matter and should not be construed as limiting the present subject matter. Thus, it will be understood that various configurations can be devised that embody the principles of the present subject matter, although not explicitly described or shown herein. Furthermore, all statements herein reciting principles, aspects, and implementations of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[0113] It should be understood that not necessarily all objectives or advantages will be achieved in accordance with any particular example described herein. Thus, for example, those skilled in the art will recognize that some examples may be engineered to achieve or optimize one advantage or advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein.

[0114] All of the processes described herein may be embodied in software code modules executed by a computing system including a computer or processor, and thereby fully automated. The code modules may be stored on any type of non-transitory computer-readable medium or other computer storage device. Some or all of the methods may be embodied in dedicated computer hardware.

[0115] Many other variations beyond those described herein will be apparent from this disclosure. For example, depending on the embodiment, certain operations, events, or functions of any of the algorithms described herein may be performed in a different order, added, merged, or omitted entirely (e.g., not all acts or events described may be necessary to implement an algorithm). Furthermore, in some examples, operations or events may be performed simultaneously rather than sequentially, for example, via multithreading, interrupt processing, or multiple processors or processor cores, or on other parallel architectures. Furthermore, different tasks or processes may be performed by different machines and / or computing systems that can function together.

[0116] The various illustrative logic blocks and modules described in connection with the embodiments disclosed herein may be implemented or performed by a machine, such as a processing unit or processor, a digital signal processor (“DSP”), an application specific integrated circuit (“ASIC”), a field programmable gate array (“FPGA”) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof, designed to perform the functions described herein. A processor may be a microprocessor, but in alternative examples, a processor may be a controller, microcontroller, or state machine, combinations thereof, or the like. A processor may include electrical circuitry for processing computer-executable instructions. In some embodiments, a processor includes an FPGA or other programmable device that performs logical operations without processing computer-executable instructions. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, multiple microprocessors, a microprocessor in combination with a DSP core, or any other such configuration.

[0117] Although described herein primarily in terms of digital technology, a processor may also include primarily analog components. A computing environment may include any type of computer system, including, but not limited to, a computer system based on a microprocessor, a mainframe computer, a digital signal processor, a portable computing device, a device controller, or a computational engine within an appliance, to name a few. Elements of a method, process, routine, or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor device, or a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, a hard disk, a removable disk, a CD-ROM, or any other form of non-transitory computer-readable storage medium. An exemplary storage medium may be coupled to the processor device such that the processor device can read information from, and write information to, the storage medium. Alternatively, the storage medium may be integrated into the processor device. The processor device and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. Alternatively, the processor device and the storage medium may reside as discrete components within a user terminal.

[0118] The processes described herein or illustrated in the figures of this disclosure may be initiated in response to an event, such as a predetermined or dynamically determined schedule, on demand when initiated by a user or system administrator, or in response to some other event. When such processes are initiated, a set of executable program instructions stored on one or more non-transitory computer-readable media (e.g., hard drives, flash memory, removable media, etc.) may be loaded into memory (e.g., RAM) of a server or other computing device. The executable instructions may then be executed by a hardware-based computer processor of the computing device. In some embodiments, such processes, or portions thereof, may be implemented in multiple computing devices and / or multiple processors, serially or in parallel.

[0119] While the flow diagrams described herein may depict operations as a sequential process, many of the operations may be performed in parallel or simultaneously. Further, the order of operations may be rearranged. A process terminates when its operations are completed. A process may correspond to a method, a procedure, an algorithm, etc. The operations of a method may be performed in whole or in part, may be performed in conjunction with some or all of the operations of other methods, and may be performed by any number of different systems, such as the systems described herein, or any portion thereof, such as a processor included in any of the systems.

[0120] In particular, conditional language such as "can," "could," "might," or "may," unless otherwise specified, is understood within the context in which it is generally used to convey that some examples include certain features, elements, and / or steps, while other examples do not. Thus, such conditional language is generally not intended to imply that the features, elements, and / or steps are in any way illustrative of the examples, or that the examples necessarily include logic for determining whether or not those features, elements, and / or steps should be included in or performed in any particular example, with or without user input or prompting.

[0121] Disjunctive language such as the phrase "at least one of X, Y, or Z" is generally understood in its context of use to indicate that an item, term, etc. can be either X, Y, or Z, or any combination thereof (e.g., X, Y, and / or Z), unless otherwise indicated. Thus, such disjunctive language generally does not and should not imply that at least one of X, at least one of Y, or at least one of Z are required for some instances to exist, respectively.

[0122] Any process descriptions, elements, or blocks in the flow diagrams described herein and / or shown in the accompanying drawings should be understood as potentially representing modules, segments, or portions of code containing executable instructions for implementing specific logical functions or elements in the process. Alternatives are included within the scope of the examples described herein, in which elements or functions may be omitted or performed in a different order than that shown or described, including substantially simultaneously or in reverse order, depending on the functionality involved, as will be understood by those skilled in the art.

[0123] It should be emphasized that many variations and modifications can be made to the above examples, and that the elements are to be understood as being among the other acceptable examples, and all such modifications and variations are intended to be included within the scope of this disclosure.

[0124] Any process descriptions, elements, or blocks in the flow diagrams described herein and / or shown in the accompanying drawings should be understood as potentially representing modules, segments, or portions of code containing executable instructions for implementing specific logical functions or elements in the process. Implementations are included within the scope of the examples described herein in which, depending on the functionality involved, elements or functions may be omitted or performed in a different order than that shown or described, including substantially simultaneously or in reverse order, as will be understood by those skilled in the art.

[0125] Unless otherwise specified, articles such as "a" or "an" should generally be construed to include one or more listed items. Thus, phrases such as "an apparatus configured as" are intended to include one or more of the listed apparatuses. Such one or more listed apparatuses may also be collectively configured to perform the stated enumeration. For example, "a processor configured to perform enumerations A, B, and C" may include a first processor configured to perform enumeration A working in conjunction with a second processor configured to perform enumerations B and C.

[0126] It will also be understood that one or more of the elements shown in the drawings / figures may also be implemented in a more separate or integrated manner, or may be removed or depicted as inoperative in certain cases, as may be useful depending on the particular application.

Claims

1. 1. A system for attaching exterior vehicle components to a vehicle assembly structure, comprising: an automated assembly cell having a respective fixture for each exterior vehicle component; a global datum for aligning the exterior vehicle part within the automated assembly cell; a clamping mechanism for holding the exterior vehicle components to their respective fixtures using vacuum clamps or other clamping means; a robotic bonding arm for applying structural adhesive to a clamped exterior vehicle component or component-receiving location on said vehicle assembly structure; a robotic part positioner for moving the clamped exterior vehicle part to a nominal position relative to the global datum to compress the structural adhesive and complete the attachment of the clamped exterior vehicle part to the vehicle assembly structure; Equipped with The system is configured to provide a bonding gap to compensate for irregularities in exterior vehicle parts, fixtures, or the underlying structure of the vehicle assembly structure.

2. The system of claim 1 , wherein the clamped exterior vehicle part is continuously moved to the nominal position relative to the global datum.

3. The system of claim 1 , wherein the clamped exterior vehicle part is moved to the nominal position simultaneously with another exterior vehicle part.

4. 10. The system of claim 1, wherein the nominal position is or corresponds to an intended or final position of the exterior vehicle part within the vehicle assembly structure as determined by design specifications.

5. The system of claim 1 , wherein the bonding gap corresponds to a difference in thermal or material properties between a bonded exterior vehicle part and the vehicle assembly structure.

6. 10. The system of claim 1, further comprising a tacking applicator for performing a tacking operation simultaneously with application of the structural adhesive to allow continued assembly of the vehicle assembly structure until the structural adhesive cures.

7. The system of claim 6 , wherein the tacking applicator is further configured to apply one or more self-piercing datums or hot melt adhesives to one or more of the exterior vehicle parts.

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