DESC:FIELD OF INVENTION

The present invention relates to a frame assembly of a truck chassis. In particular, the present invention relates to a system for making a frame assembly of a truck chassis. More particularly, the present invention relates to a system for making a pre-squaring frame assembly of a truck chassis.

BACKGROUND OF THE INVENTION

The conventional pre-squaring process for making frame assembly of truck chassis at the plant of other Original Equipment Manufacturers includes the following process steps:

• Placing individual components on the base plate and pulling manually.

• Using the base plate only for resting the components.

• Separating the pair of long members and manually aligning the same with the cross members.

• Existing practice within India and in foreign countries is labor-intensive.

PRIOR ART

Patent US 6615478 B2 discloses a chassis inverter consisting of a set of clamps that hold a mobile vehicle chassis and a hydraulic driven rotary actuator. The apparatus and an overhead crane system provide a method of inverting and transferring chassis in a short time period needed to meet high-volume vehicle manufacturing needs. The apparatus consists of two c-shaped clamps that cradle the chassis. The clamps are assembled to a shaft that is driven by a hydraulic cylinder through a sprocket and chain arrangement that provides a full inversion of the chassis. One clamp has a motorized trolley that provides adjustment needed for handling chassis of widely varying wheelbase.; The process involves an overhead crane system with a bridge crane section that provides the necessary broadside loading motion, and an interlocking monorail section that allows the hoist carriers to exit the bridge and travel perpendicularly to the inverting apparatus' loading direction. This patent escribes the chassis inversion process during assembly.

Patent US 7980594 B2 discloses a chassis inverter consisting of a set of clamps that hold a mobile vehicle chassis and a hydraulic driven rotary actuator. The apparatus and an overhead crane system provide a method of inverting and transferring chassis in a short time period needed to meet high-volume vehicle manufacturing needs. The apparatus consists of two c-shaped clamps that cradle the chassis. The clamps are assembled to a shaft that is driven by a hydraulic cylinder through a sprocket and chain arrangement that provides a full inversion of the chassis. One clamp has a motorized trolley that provides adjustment needed for handling chassis of widely varying wheelbase.; The process involves an overhead crane system with a bridge crane section that provides the necessary broadside loading motion, and an interlocking monorail section that allows the hoist carriers to exit the bridge and travel perpendicularly to the inverting apparatus' loading direction. This patent describes about the assembly of different chassis sections.

US 2014252807 A1 discloses about assembly of the top and bottom channel sections of the chassis. It describes a heavy truck frame and a method for manufacturing a heavy truck frame having side-rails with a configuration of a top C-section and a bottom C-section and a vertical insert so as to reduce weight and maintain the stiffness requirements and improve payload. The optimal distances between a top C-section and a bottom C-section can vary according to the part of the frame and vehicle requirements.

DISADVANTAGES WITH THE PRIOR ART

However, the problem with the conventional processes for making frame assembly of truck chassis have the following disadvantages:

• No prior art document or literature describes an assembly process for the pre-squaring of frame assembly of for truck chassis.

• No process is known for handling of chassis long member during the input condition thereof.

• No process is known for separating the chassis long members during framing / squaring operation thereof.

Therefore, there is an existing need for providing processes and systems to carry out abovementioned handling and separating the chassis long members during framing / pre-squaring operation thereof.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An object of the present invention is to provide a cost-effective system for carrying out the frame assembly of truck chassis.

Another object of the present invention is to provide a simplified system for carrying out the pre-squaring of frame assembly of truck chassis.

Still another object of the present invention is to provide a system for handling of truck chassis long members during the input condition thereof.

Yet another object of the present invention is to provide a system for separating the chassis long members during framing / squaring operation.

A further object of the present invention is to provide an efficient process for pre-squaring frame assembly of truck chassis frame assembly by using the system configured in accordance with the present invention.

These and other objects and advantages of the present invention will become more apparent from the following description, when read with the accompanying figures of drawing, which are however not intended to limit the scope of the present invention in any way.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided an automated system for making pre-squaring frame assembly made from a plurality of steel channel members received from the storage pallets thereof and having a mechanism for transfer of the members from the pallets for indexing and for pushing the members to be placed in a predefined configuration according to the pre-squaring frame assembly for a corresponding truck chassis frame model.

Typically, the pre-squaring frame assembly comprises steel channel members, preferably at least one pair of long members and a plurality of cross members positioned therebetween and the number of the cross members selected depending on the pre-squaring frame assembly configuration for a respective truck chassis frame model to be made.

Typically, the automated system comprises:

• a storage pallet for the long-member pairs required for making the pre-squaring frame assembly for a respective truck chassis frame assembly;

• a sequencing and transfer table for long member pairs; and

• an arrangement for lifting and transferring the long member pairs and cross-members.

Typically, the long member pairs are placed on the sequencing and transfer table by means of the lifting and transferring arrangement and transferred in a direction transverse to the storage pallet.

Typically, the automated system further comprises a mechanism is provided for pushing the long member pair in a longitudinal direction.

Typically, the automated system further comprises a pre-squaring fixture provided with a plurality of clamps for clamping long member pairs and cross-members for making pre-squaring frame assembly thereon.

Typically, the automated system further comprises an indexing and transfer mechanism provided for indexing or turning the long member pair from a horizontal orientation to a vertical orientation for further processing thereof.

Typically, the pre-squaring fixture comprises a pair of electromagnets for holding the long members; a pair of pneumatic cylinders for retracting the long members in transverse direction to mutually separate by a distance predefined according to the cross members’ length; and a pair of locating pins for locating the pair of separated long members in place.

Typically, the cross members are placed between separated long members at a predetermined pitch or configuration for forming a corresponding pre-squaring frame assembly by loosely tightening fasteners for further processing to make a truck chassis.

In accordance with the present invention, there is also provided a method for making a pre-squaring frame assembly by means of the automated system for a corresponding truck chassis frame model, the method comprises the steps of:

• receiving C-in-C long members and cross members in a respective storage pallet by means of a lifting and transferring arrangement;

• sequentially transferring one of the long member pairs on a sequencing and transfer table and indexing the same from a horizontal to vertical orientation by means of the indexing and transfer mechanism and transferring the same by pushing it towards the frame pre-squaring assembly fixture by means of the pusher mechanism;

• holding the long member pair by means of an electromagnet disposed on either side thereof;

• retracting the long members apart in transverse direction by a distance predefined according to the cross members’ length using the pair of pneumatic cylinders;

• placing the pair of separated long members in place by means of the pair of locating pins and clamping of the long members at suitable location on the pre-squaring assembly fixture to maintain the position/datum point thereof;

• locating a predetermined number of cross members on the base of the pre-squaring assembly fixture between the separated and clamped long members;

• lifting the base of the pre-squaring assembly fixture in a vertical direction to match the position of the clamped long members and maintaining a suitable height for obtaining the selected configuration of the pre-squaring frame assembly;

• loosely tightening the clamped long members along with the cross members located therebetween to complete the loosely assembled pre-squaring frame assembly; and

• transferring the loosely assembled pre-squaring frame assembly of the truck chassis from the pre-squaring fixture to a universal framer by means of an overhead crane for further tightening and obtaining the geometrically accurate shape thereof

DESCRIPTION OF THE INVENTION

To overcome the disadvantages associated with the systems and processes for making the frame assembly, particularly pre-squaring frame assembly of truck chassis, in accordance with the present invention, a system is provided to facilitate pre-squaring frame assembly for different truck chassis configurations.

This novel method has the following main process steps:

• Receiving of a pair of long members from the supplier in C-in-C (channel in channel) condition.

• Changing paired long members (‘C’ IN ‘C’) from horizontal to vertical and transfer the same to the frame pre-squaring frame fixture.

• Locating the paired long members on the pre-squaring assembly fixture by using locating pins to maintain the position/datum point of the frame assembly.

• Clamping of the paired long members at suitable location on the pre-squaring assembly fixture by using the electromagnets.

• Pneumatically separating the paired long members received from the supplier in “C” in “C” condition.

• Placing the cross-members on the fixture by maintaining a suitable height to facilitate the assembly of side members and cross members.

• Lifting the base fixture in a vertical direction to match the position of the long member.

• Closing the pair of long members and matching the cross members to complete the frame assembly.

• Loosely tightening the fasteners of the completed frame assembly.

Accordingly, the process-flow of the pre-squaring frame assembly of the truck chassis according to the present invention comprises the following process steps:
• Paired long Members are transferred from the storage pallets to the sequencing and transfer table using crane and belt arrangement.

• Indexing (900 tilting) of the long member pair and transferring the same on the pre-squaring fixture.

• Clamping the Long members for separation by using a set of electromagnets for holding the long members and pulling the same apart by using pneumatic cylinders.

• Placing a predetermined number of cross members in a defined configuration between separated long members clamped on the pre-squaring fixture to form an assembled pre-squaring frame for truck chassis.

• Loosely tightening the fasteners on the assembled pre-squaring frame.
• Transferring the loosened assembled frame from the pre-squaring fixture to the universal framer for further tightening and obtaining the geometric accuracies as per drawing.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described with reference to the accompanying drawings.

Figure 1 shows a system for making a pre-squaring frame assembly of the truck chassis with the long member pair being transferred from the storage pallets to the sequencing and transfer table by using a crane and belt arrangement.

Figure 2 shows an enlarged detailed view of the system of Figure 1 depicting the long member pair being indexed (tilted by 900) and transferred on the pre-squaring fixture of Figure 1.

Figure 3 shows the system of Figure 1 depicting the clamping of long members for separating the same by using a set of electromagnets for holding the long members and pulling the same apart by using pneumatic cylinders.

Figure 4 shows the system of Figure 1 depicting the separation of long members on the pre-squaring fixture.

Figure 5 shows the placing of the cross-members across the long members on the pre-squaring fixture configured in accordance with the present invention.

Figure 6 shows the loosely assembled frame transferred from the pre-squaring fixture of Figure 5 to the universal framer.

DETALED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described with reference to the accompanying drawings.

Figure 1 shows a system for making a pre-squaring frame assembly of the truck chassis depicting the long member pairs 10 received from the supplier in C-in-C (Channel in Channel) condition (Inset Figure 1a) and being transferred from the storage pallets 100 to the sequencing and transfer table 20 by the operator Op by using a crane and belt arrangement 30 to the pre-squaring fixture 50 of the system for making a pre-squaring frame assembly of the truck chassis and configured in accordance with the present invention.

Figure 2 shows an enlarged detailed view of the system of Figure 1 depicting a long member pair being indexed (tilted by 900) and transferred on the pre-squaring fixture configured in accordance with the present invention. Here, a pusher 40 is provided for transferring the long member pair 10 to the pre-squaring fixture 50. The long members pairs 10 disposed over a long member sequencing and transfer table 20 being transferred in the direction A1 and being indexed by using a long member indexing and transfer mechanism 60, which sequentially indexes (I) the long member pairs 10 from a horizontal to a vertical position thereof and transfers the vertically disposed long member pair 10 to the pre-squaring fixture 50 in the direction of the arrows A2.

Figure 3 shows the clamping of pair of long members 10 for separating the same by using a set of electromagnets 80 for holding the long members and pulling the same apart by using pneumatic cylinders 70 (not shown here). The long member pair 10 in C-in-C condition is held between two locating pins (PLP) 90 provided on the front end of the frame fixture 50. Two pairs of electromagnets 80 are disposed at either end of the pre-squaring fixture 50, one electromagnet coupled to at least one pneumatic cylinder 70 each on either longitudinal side of the long member pair 10. After the pusher 40 has pushed the indexed long member pair 10 between the electromagnets 80, the principle locating pins 90 locates the long member pair 10 between the same for separating the individual long member of the pair 10 by pulling in direction A3.

Figure 4 shows the separation of individual long members 10 placed on the pre-squaring fixture 50 and held by the electromagnets 80 thereof. The pneumatic cylinders 70 (not visible here) are retracted to pull back the long members 10 by a distance W predefined by the length of the cross-members to be placed therebetween.

Figure 5 shows the placing of the cross-members 15 across (disposed between) the long members 10 on the pre-squaring fixture 50 configured in accordance with the present invention. The length of the cross-members 15 is equal to the distance W available between the long members 10.

Figure 6 shows the loosely assembled frame of the truck chassis CH being transferred from the pre-squaring fixture 50 to the universal framer 200 by means of an overhead crane 35 for further tightening and obtaining the geometric accuracies thereof as per the drawings.

TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

The system and process for making a pre-squaring frame assembly of the truck chassis configured in accordance with the present invention has the following technical and economic advantages:

• No fatigue for operators.

• Reducing the work content.
• Flexibility of manufacturing.

• Deployable for manufacturing truck chassis for all types of commercial vehicles, e.g. HCV, MCV and ICV.

• User friendly system and process.

In the previously detailed description, different features have been summarized for improving the conclusiveness of the representation in one or more examples. However, it should be understood that the above description is merely illustrative, but not limiting under any circumstances. It helps in covering all alternatives, modifications and equivalents of the different features and exemplary embodiments.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept. Many other examples are directly and immediately clear to the skilled person because of his/her professional knowledge in view of the above description.

These innumerable changes, variations, modifications, alterations may be made and/or integrations in terms of materials and method used may be devised to configure, manufacture and assemble various constituents, components, subassemblies and assemblies according to their size, shapes, orientations and interrelationships. Therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

The exemplary embodiments described in this specification are intended merely to provide an understanding of various manners in which this embodiment may be used and to further enable the skilled person in the relevant art to practice this invention. The description provided herein is purely by way of example and illustration.

Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to implies including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps. In the claims and the description, the terms “containing” and “having” are used as linguistically neutral terminologies for the corresponding terms “comprising”.

The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention. Furthermore, the use of the term “one” shall not exclude the plurality of such features and components described.

Also, any reference herein to the terms ‘left’ or ‘right, ‘up’ or ‘down, or ‘top’ or ‘bottom’ are used as a matter of mere convenience, and are determined by standing at the rear of the machine facing in its normal direction of travel.

The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

The various features and advantageous details are explained with reference to the non-limiting embodiment/s in the above description in accordance with the present invention.

The descriptions of well-known components and manufacturing and processing techniques are consciously omitted in this specification, so as not to unnecessarily obscure the specification.

Furthermore, the various components shown or described herein for any specific application of this invention can be widely known or used in the art by persons skilled in the art and each will likewise not therefore be discussed in significant detail. When referring to the figures, like parts are numbered the same in all of the figures. ,CLAIMS:We claim:

1. An automated system for making pre-squaring frame assembly made from a plurality of steel channel members received from the storage pallets thereof and having a mechanism for transfer of said members from said pallets for indexing and for pushing said members to be placed in a predefined configuration according to said pre-squaring frame assembly for a corresponding truck chassis frame model.

2. Automated system as claimed in claim 1, wherein said pre-squaring frame assembly comprises steel channel members, preferably at least one pair of long members (10) and a plurality of cross members (15) positioned therebetween and the number of the cross members selected depending on the pre-squaring frame assembly configuration for a respective truck chassis frame model to be made.

3. Automated system as claimed in claim 2, wherein said automated system comprises:

• a storage pallet (100) for said long-member pairs (10) required for making said pre-squaring frame assembly for a respective truck chassis frame assembly;

• a sequencing and transfer table (20) for long member pairs (10); and

• an arrangement (30) for lifting and transferring said long member pairs (10) and cross-members (15).

4. Automated system as claimed in claim 3, wherein said long member pairs (10) are placed on said sequencing and transfer table (20) by means of said lifting and transferring arrangement (30) and transferred in a direction (A1) transverse to said storage pallet (100).

5. Automated system as claimed in claim 3, wherein said automated system further comprises a mechanism (40) is provided for pushing the long member pair (10) in a longitudinal direction (A2).
6. Automated system as claimed in claim 4, wherein said automated system further comprises a pre-squaring fixture (50) provided with a plurality of clamps (55) for clamping long member pairs (10) and cross-members (15) for making pre-squaring frame assembly thereon.

7. Automated system as claimed in claim 5, wherein said automated system further comprises an indexing and transfer mechanism (60) provided for indexing or turning said long member pair (10) from a horizontal orientation to a vertical orientation for further processing thereof.

8. Automated system as claimed in claim 6, wherein said pre-squaring fixture (50) comprises a pair of electromagnets (70) for holding the long members; a pair of pneumatic cylinders (80) for retracting the long members (10) in transverse direction (A3) to mutually separate by a distance (W) predefined according to said cross member’s length; and a pair of locating pins (90) for locating said pair of separated long members (10) in place.

9. Automated system as claimed in claim 2, wherein said cross members are placed between separated long members (10) at a predetermined pitch or configuration for forming a corresponding pre-squaring frame assembly by loosely tightening fasteners for further processing to make a truck chassis.

10. A method for making a pre-squaring frame assembly by means of the automated system as claimed in anyone of the claims 1 to 9, wherein said method comprises the steps of:

• receiving channel-in-channel (C-in-C) long members (10) and cross members (15) in a respective storage pallet (100) by means of a lifting and transferring arrangement (30);

• sequentially transferring one of said long member pairs (10) on a sequencing and transfer table (20) and indexing the same from a horizontal to vertical orientation by means of said indexing and transfer mechanism (60) and transferring the same by pushing it towards the frame pre-squaring assembly fixture by means of said pusher mechanism (40);
• holding said long member pair (10) by means of an electromagnet (70) disposed on either side thereof;

• retracting said long members (10) apart in transverse direction (A3) by a distance (W) predefined according to said cross members’ length using said pair of pneumatic cylinders (80);

• placing said pair of separated long members (10) in place by means of said pair of locating pins (90) and clamping of said long members at suitable location on said pre-squaring assembly fixture (50) to maintain the position/datum point thereof;

• locating a predetermined number of cross members (15) on the base of said pre-squaring assembly fixture (50) between said separated and clamped long members (10);

• lifting the base of said pre-squaring assembly fixture (50) in a vertical direction to match the position of said clamped long members (10) and maintaining a suitable height for obtaining the selected configuration of said pre-squaring frame assembly.

• Loosely tightening said clamped long members (10) along with said cross members (15) located therebetween to complete said loosely assembled pre-squaring frame assembly; and

• transferring said loosely assembled pre-squaring frame assembly of the truck chassis (CH) from said pre-squaring fixture (50) to a universal framer (200) by means of an overhead crane (35) for further tightening and obtaining the geometrically accurate shape thereof.

Dated: this 31st day of January 2017. SANJAY KESHARWANI
APPLICANT’S PATENT AGENT