GB2312401A - A method of assembling a motor vehicle in which interior fittings are inserted through the roof aperture - Google Patents

Abstract

The assembly line 21 comprises an overhead conveyor 22, a track 23 carrying partially assembled car bodies 24, each of which has a roof aperture 25, and a pick face 26 alongside the track 23. During assembly, one or more internal fittings, eg fascia, heater, trim, lighting, carpets, seating and seat belt harness, are supplied by the conveyor 22 on a just-in-time basis and inserted through the aperture 25 and assembled on to the body 24 of the motor vehicle. The operators themselves gain access to the interior of the body via the door apertures 27. The roof aperture 25 is then closed by means of a roof panel 28. This method makes assembly easier and shortens assembly lines.

Description

A METHOD OF ASSEMBLING A MOTOR VEHICLE The invention relates to a method of assembling a motor vehicle and in particular to the assembly of internal fittings within a body of the vehicle.

Mass produced motor vehicles are conventionally assembled on an assembly line. A partially assembled motor vehicle body passes along the assembly line and a large number of parts are fitted to it, the parts being located alongside the assembly line on a so called "pick face".

Interior fittings, such as facia, seat belt harnesses, interior trim, seats, carpets etc, have to be transferred from the pick face to the interior of the vehicle body by passing the fittings through door apertures. Other parts in addition to the interior fittings also need to be assembled on the vehicle body. However it is presently ergonomically difficult for operators to assemble other parts on the vehicle body at the same time as the interior fittings are being assembled since there is limited space available at the pick face over a given length of assembly line. Therefore the interior fittings and other parts are conventionally laid out over a considerable length of the assembly line for ease of assembly of the vehicle.

It is an object of the invention to provide a method of assembling a vehicle which will enable the length of the assembly line to be reduced by increasing the density of assembly operations which take place.

According to a first aspect of the invention there is provided a method of assembling a motor vehicle on an assembly line comprising the steps of; providing a partially assembled motor vehicle body defining a roof aperture; supplying an interior fitting for assembly on to the vehicle body; introducing the interior fitting into the motor vehicle body through the roof aperture and closing the roof aperture with a roof panel.

By utilising the roof aperture in that way, interior fittings, for example the facia, can be supplied from an overhead conveyor thereby enabling an increased number of parts to be presented for assembly over a given length of assembly line. Therefore, the method reduces work in progress and increases the response time to changing customer demand. Also, the method reduces ergonomically unacceptable movements operators have to undertake and thus may reduce work-related injuries. Furthermore, the method enables the number of parts alongside the assembly line to be reduced, thus making the assembly area safer for the operators.

Preferably the method comprises the step of assembling exterior fittings on to the motor vehicle body at the same time as the interior fittings introduced through the roof aperture are being assembled on to the motor vehicle body.

The exterior fittings may be supplied from a pick face alongside the assembly line as before.

The interior fittings may comprise a heater, a facia, interior trim, seat belt harnesses, a light fitting, carpeting and/or seating.

The exterior fittings may comprise bumpers, insulation, glazing, external trim and/or a cooling pack.

According to a second aspect of the invention there is provided a motor vehicle constructed by a method according to the first aspect of the invention or any of the consistory clauses relating thereto.

A method of assembling a motor vehicle in accordance with the invention will now be described by way of example, with reference to the accompanying drawings in which: Fig 1 is a schematic diagram showing a section of an assembly line illustrating a conventional assembly sequence and Fig 2 is a schematic diagram showing a section of an assembly line illustrating an assembly sequence according to the present invention.

Referring firstly to Fig 1, an assembly line for motor vehicles is indicated generally at 11 and comprises a track 13 carrying partially assembled car bodies 14. The bodies 14 have respective roof panels 15.

Fig 1 shows the track 13 moving in the direction of arrow "A" during assembly of internal fittings into the bodies 14. A seat belt harness (not shown) is first passed into the interior of the body 14 through a selected door aperture 16 and fitted in position. Next, carpeting (not shown) is passed through a selected door aperture 16 and if fitted to the interior of the body 14. That is followed in Fig 1 by a heater and facia (not shown). The interior fittings are provided alongside the track 13 on a pick face 17 in known manner.

Exterior fittings such as bumpers and body trim must also be fitted to the vehicle body 14 and it will be necessary to do that either upstream or downstream of the section of assembly line shown in Fig 1.

Fig 2 shows an assembly sequence according to the invention. The assembly line 21 comprises an overhead conveyor 22, a track 23 carrying partially assembled car bodies 24, each of which defines a roof aperture 25, and a pick face 26 alongside the track 23.

Interior fittings are placed into the interior of each body 24 through the roof aperture 25. The fittings may be supplied by the overhead conveyor 22 which supplies the interior fittings to operator on a just-in-time basis. The conveyor 22 provides a second pick face. The operators themselves gain access to the interior of the motor vehicle body 24 through door apertures 27.

The sequence in Fig 2 shows a seat belt harness entering the body 24 through the roof cavity 25. Since the seat belt harness is supplied from above, the operator need not step out of the vehicle to pick up the harness from the pick face 26. Therefore, there is room on at least one side of the track 23 for operators to fit external trim and other external parts from the pick face 26.

The operator in the interior of the body now remains within the body 24 to install carpeting which enters the body through the roof cavity 25. At the same time that this operation is taking place, underbonnet insulation and quarter light glazing can be assembled on to the exterior of the body 24 by other operators. Similarly the heater can be assembled in the body 24 at the same time as a cooling pack and a facia at the same time as the front and rear bumper.

Once the interior fittings have been assembled inside the body 24 the roof aperture 25 is then closed by addition of a roof panel 28 shown in broken lines.

In accordance with the invention parts for assembly of the vehicle can be carried on the conveyor 22 and laid out on the pick face 26. Previously, all the parts would have been spread out along the pick face 26. Therefore the assembly line can effectively be shortened by using a method according to the invention.

Claims (1)

1. A method of assembling a motor vehicle on an assembly line comprising the steps of providing a partially assembled motor vehicle body defining a roof aperture, supplying one or more interior fittings for assembly on to the vehicle body, introducing the interior fittings through the roof aperture and closing the roof aperture with a roof panel.

2 A method according to Claim 1 wherein the interior fittings are supplied via an overhead conveyor.

3 A method according to Claim 3, wherein the overhead conveyor delivers the interior fittings on a just-in time basis from an off track pick face.

4 A method according to any previous claim, wherein exterior fittings are assembled on to the motor vehicle body at the same time as the interior fittings are assembled into the motor vehicle body.

5 A method according to Claim 5, wherein the exterior fittings are supplied from a pick face alongside the assembly line.

6 A method according to any previous claim, wherein the interior fittings comprise a heater, facia, interior trim, seat belt harnesses, a light fitting, carpeting and/or seating.

7 A method according to Claims 5 or 6, wherein the exterior fittings comprise bumpers, insulation, glazing, external trim and/or cooling packs.

9 A method of assembling a motor vehicle substantially as hereinbefore described with reference to Fig 2 of the accompanying drawings.

10 A motor vehicle constructed by a method according to any preceding claim.