U.S. patent application number 09/865713 was filed with the patent office on 2001-12-06 for process and apparatus for assembling vehicle body frame for motorcycle.
This patent application is currently assigned to Honda Giken Kogyo Kabushiki Kaisha. Invention is credited to Hoshi, Hisashi, Ishizaki, Isamu, Miwa, Teiji, Ryu, Hidekazu, Yamaoka, Naoji.
Application Number | 20010047591 09/865713 |
Document ID | / |
Family ID | 27481336 |
Filed Date | 2001-12-06 |
United States Patent
Application |
20010047591 |
Kind Code |
A1 |
Yamaoka, Naoji ; et
al. |
December 6, 2001 |
Process and apparatus for assembling vehicle body frame for
motorcycle
Abstract
In assembling a vehicle body frame for a motorcycle by welding
front and rear frame subassemblies to each other, the following
steps are carried out: a step of positioning left and right rear
portions of the front frame subassembly by a pair of front
positioning device movable at least in a widthwise direction of the
vehicle body frame, a step of clamping a head pipe by a front clamp
device which is capable of being moved in vertical and longitudinal
directions of the vehicle body frame and is capable of being tilted
longitudinally, a step of positioning left and right rear portions
of the rear frame subassembly by a pair of rear positioning device
movable in the longitudinal, widthwise and vertical directions of
the vehicle body frame, a step of clamping left and right front
portions of the rear frame subassembly by a pair of rear clamp
means movable in the longitudinal, widthwise and vertical
directions of the vehicle body frame, and a step of welding the
front and rear frame subassemblies to each other. Thus, it is
possible to provide general-purpose properties to reduce the
equipment cost.
Inventors: |
Yamaoka, Naoji; (Sayama-shi,
JP) ; Ryu, Hidekazu; (Sayama-shi, JP) ; Miwa,
Teiji; (Sayama-shi, JP) ; Ishizaki, Isamu;
(Sayama-shi, JP) ; Hoshi, Hisashi; (Sayama-shi,
JP) |
Correspondence
Address: |
ARENT FOX KINTNER PLOTKIN & KAHN
Suite 600
1050 Connecticut Avenue, N.W.
Washington
DC
20036-5339
US
|
Assignee: |
Honda Giken Kogyo Kabushiki
Kaisha
|
Family ID: |
27481336 |
Appl. No.: |
09/865713 |
Filed: |
May 29, 2001 |
Current U.S.
Class: |
29/897.2 |
Current CPC
Class: |
Y10T 29/534 20150115;
Y10T 29/49901 20150115; Y10T 29/53365 20150115; Y10T 29/53978
20150115; Y10T 29/53961 20150115; B23K 37/0426 20130101; Y10T
29/49998 20150115; Y10T 29/53039 20150115; Y10T 29/4978 20150115;
Y10T 29/53983 20150115; B23P 2700/50 20130101; B23K 2101/006
20180801; Y10T 29/49622 20150115 |
Class at
Publication: |
29/897.2 |
International
Class: |
B21D 053/88 |
Foreign Application Data
Date |
Code |
Application Number |
May 30, 2000 |
JP |
2000-164757 |
May 30, 2000 |
JP |
2000-164758 |
May 30, 2000 |
JP |
2000-164759 |
May 30, 2000 |
JP |
2000-164760 |
Claims
What is claimed is:
1. A process for assembling a vehicle body frame for a motorcycle
by welding a front frame subassembly having a head pipe at a front
end thereof and a rear frame subassembly to each other to assemble
the vehicle body frame for the motorcycle, comprising a first step
of positioning left and right rear portions of the front frame
subassembly by a pair of front positioning means movable at least
in a direction of a Y-axis established in a widthwise direction of
the vehicle body frame, a second step of clamping the head pipe at
the front end of the front frame subassembly by a front clamp means
which is capable of moving in directions of Z- and X-axes
established in vertical and longitudinal directions of said vehicle
body frame, and is capable of tilting about an axis extending along
the Y-axis, a third step of positioning left and right rear
portions of said rear frame subassembly by a pair of rear
positioning means movable in the directions of the X-, Y- and
Z-axes, a fourth step of clamping left and right front portions of
said rear frame subassembly by a pair of rear clamp means movable
in the directions of the X-, Y- and Z-axes, and a fifth step of
welding the rear frame subassembly positioned relative to the front
frame subassembly and the front frame subassembly to each
other.
2. An apparatus for assembling a vehicle body frame for a
motorcycle by welding a front frame subassembly having a head pipe
at a front end thereof and a rear frame subassembly to each other,
comprising a pair of front positioning means capable of positioning
left and right rear portions of the front frame subassembly, a
front clamp means capable of clamping the head pipe at the front
end of the front frame subassembly, a pair of rear positioning
means capable of positioning left and right rear portions of the
rear frame subassembly, a pair of rear clamp means capable of
clamping left and right front portions of the rear frame
subassembly, a pair of front positioning drive means for moving
said front positioning means at least in a direction of a Y-axis
established in a widthwise direction of said vehicle body frame,
respectively, a front clamp drive means which is capable of moving
said front clamp means in directions of Z- and X-axes established
in vertical and longitudinal directions of said vehicle body frame
and is capable of tilting said front clamp means about an axis
extending along the Y-axis, a pair of rear positioning drive means
capable of moving said rear positioning means in the directions of
X-, Y- and Z-axes, respectively, a pair of rear clamp drive means
capable of moving said rear clamp means in the directions of X-, Y-
and Z-axes, respectively, and a control unit for controlling the
operations of said drive means, so that said front positioning
means, said front clamp means, said rear positioning means and said
rear clamp means are brought into positions previously determined
depending on the type of the vehicle body frame for the motorcycle,
which is to be assembled.
3. An apparatus for assembling a vehicle body frame for a
motorcycle according to claim 2, wherein said front clamp means
includes a plurality of supporting pins capable of being fitted
into lower ends of a plurality of types of head pipes, a
pin-supporting plate for fixedly supporting one of said supporting
pins, while disposing said one of the pins at a location below the
head pipe, a pushing member capable of being brought into
engagement with an upper end of the head pipe fitted at a lower end
thereof over said one of the supporting pins, irrespective of the
type of the head pipe, thereby clamping said head pipe between said
pushing member and said one of the supporting pins, and a cylinder
for providing pushing force for pushing said head pipe from above
to said pushing member.
4. An apparatus for assembling a vehicle body frame for a
motorcycle according to claim 3, further including an arm, at one
end of which said pushing member is mounted, said cylinder being
disposed at a fixed position to have an axis parallel to an axis of
the head pipe and connected to the other end of said arm through a
connecting pin, a cam plate fixedly disposed with a position
thereof fixed relative to said cylinder, and having a cam bore
comprising a first bore portion extending in parallel to the axis
of said head pipe, and a second bore portion connected to an upper
end of said first bore portion and inclined in such a direction
that said second bore portion is more spaced apart from said head
pipe at an upper location, and a roller supported at an
intermediate portion of said arm and capable of being rolled within
said cam bore.
5. An apparatus for assembling a vehicle body frame for a
motorcycle according to claim 3 or 4, wherein said pin-supporting
plate is disposed at a location below said head pipe for turning
movement about the axis parallel to the axis of said head pipe;
said supporting pins individually corresponding to the plurality of
types of head pipes are fixed to said supporting plate, so that
said supporting pins are disposed at a plurality of locations
equally spaced apart from one another in a circumferential
direction of said pin-supporting plate; and said apparatus further
includes an index mechanism connected to said pin-supporting plate
to alternatively bring one of the plurality of supporting pins to a
position below said head pipe.
6. An apparatus for assembling a vehicle body frame for a
motorcycle according to claim 2, wherein each of said front
positioning means and said rear positioning means includes a guide
wall which has a guide bore corresponding to a positioning bore
provided in a positioned member forming a portion of said front
frame subassembly or said rear frame subassembly to extend in a
widthwise direction of said vehicle body frame, said guide wall
being opposed to an outer side surface of said positioned member in
a position where said guide bore corresponds to said positioning
bore, a cylinder disposed coaxially with an axis of said guide bore
on a side of said guide wall opposite from said positioned member,
a plurality of movable rods which are capable of being fitted into
said guide bore for selective interposition as well as removable
insertion between said cylinder and said guide wall, each of said
movable rods being releasably connected at one end thereof to said
cylinder, and a plurality of types of positioning pins, each of
which is formed into such a shape as to be capable of fitting into
the positioning bore in any of a plurality of types of said
positioned members, said positioning pins being individually fixed
to the other ends of said movable rods.
7. An apparatus for assembling a vehicle body frame for a
motorcycle according to claim 6, further including a rod-supporting
plate disposed between said guide wall and said cylinder for
turning movement about an axis parallel to the axis of said guide
bore; said movable rods being disposed at locations equally spaced
apart from one another in the circumferential direction of said
rod-supporting plate and retained on said rod-supporting plate for
sliding movement in a direction parallel to the axis of said guide
bore, and an index motor connected to said rod-supporting plate for
driving said rod-supporting plate in turning movement, so that one
of said movable rods can be alternatively brought to a position
between said cylinder and said guide bore.
8. An apparatus for assembling a vehicle body frame for a
motorcycle according to claim 2, wherein said rear clamp means
formed to clamp and retain a pipe-shaped frame member forming a
portion of said vehicle body frame and extending in the
substantially longitudinal direction of said vehicle body frame
includes a movable support which is capable of being moved in the
longitudinal, widthwise and vertical directions of said vehicle
body frame and is capable of being stopped at any position, a
receiving member which is formed into a substantially V-shape to
open upwards in a plane intersecting a lengthwise direction of said
frame member, and is fixed to said movable support so as to be
disposed below said frame member, a pushing member supported on
said movable support for swinging movement in said plane to
sandwich said frame member between said pushing member and said
receiving member, and a drive mechanism provided between said
movable support and said pushing member to drive said pushing
member in swinging movement, each of surfaces of said receiving
member and said pushing member opposed to said frame member being
formed into such a shape as to be brought into spherical contact
with said frame member.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to improvements of a process
and apparatus for assembling a vehicle body frame for a motorcycle
by welding a front frame subassembly having a head pipe at a front
end thereof and a rear frame subassembly to each other.
[0003] 2. Description of the Related Art
[0004] A process for assembling a vehicle body frame for a
motorcycle is conventionally known from Japanese Patent Publication
No.4-749, for example. In this process, a center member such as a
head pipe and a cross member is retained by a center jig, and left
and right side frame members forming a vehicle body frame in
cooperation with the center member are retained by a pair of left
and right side jigs, respectively. In a state in which both of the
side jigs have been righted, the side members are welded to
opposite sides of the center member to assemble the vehicle body
frame.
[0005] In the above conventionally known process, however, an
exclusive center jig and exclusive side jigs corresponding to the
type of the vehicle body frame are required. To assemble a
plurality of types of vehicle body frames for motorcycles, center
jigs and side jigs corresponding to the types must be prepared,
resulting in an increased equipment cost.
SUMMARY OF THE INVENTION
[0006] The present invention has been accomplished in view of the
above circumstances, and it is an object of the present invention
to provide a process and apparatus for assembling a vehicle body
frame for a motorcycle, wherein the general-purpose properties are
provided to accommodate the assembling of any of a plurality of
types of vehicle body frames for motorcycles, thereby providing a
reduction in equipment cost.
[0007] To achieve the above object, according to a first aspect and
feature of the present invention, there is provided a process for
assembling a vehicle body frame for a motorcycle by welding a front
frame subassembly having a head pipe at a front end thereof and a
rear frame subassembly to each other to assemble the vehicle body
frame for the motorcycle, comprising a first step of positioning
left and right rear portions of the front frame subassembly by a
pair of front positioning means movable at least in a direction of
a Y-axis established in a widthwise direction of the vehicle body
frame, a second step of clamping the head pipe at the front end of
the front frame subassembly by a front clamp means which is capable
of moving in directions of Z- and X-axes established in vertical
and longitudinal directions of the vehicle body frame, and is
capable of tilting about an axis extending along the Y-axis, a
third step of positioning left and right rear portions of the rear
frame subassembly by a pair of rear positioning means movable in
the directions of the X-, Y- and Z-axes, a fourth step of clamping
left and right front portions of the rear frame subassembly by a
pair of rear clamp means movable in the directions of the X-, Y-
and Z-axes, and a fifth step of welding the rear frame subassembly
positioned relative to the front frame subassembly and the front
frame subassembly to each other.
[0008] With such process, the pair of front positioning means for
positioning the left and right rear portions of the front frame
subassembly are movable at least in the widthwise direction of the
vehicle body frame for the motorcycle, and the front clamp means
for clamping the head pipe at the front end of the front frame
subassembly is movable in the longitudinal and vertical directions
of the vehicle body frame for the motorcycle and tiltable in the
longitudinal direction of the vehicle body frame. Therefore, in a
state in which the left and right rear portions of the front frame
subassembly have been positioned by the front positioning means,
changes in position and attitude of the head pipe caused by the
change in type of the front frame subassembly can be covered by the
movement of the front clamp means in the longitudinal and vertical
directions and the tilting of the front clamp means about the
Y-axis, whereby the front frame subassembly can be positioned and
supported with a good accuracy. In addition, the pair of rear
positioning means for positioning the left and right rear portions
of the rear frame subassembly are movable in the longitudinal,
widthwise and vertical directions of the vehicle body frame for the
motorcycle, and the pair of rear clamp means for clamping the left
and right front portions of the rear frame subassembly are movable
in the longitudinal, widthwise and vertical directions of the
vehicle body frame for the motorcycle. Therefore, even if the type
of the rear frame subassembly is changed, the rear frame
subassembly can be positioned and supported with a good accuracy
relative to the front frame subassembly, thereby providing
general-purpose properties to accommodate the assembling of any of
a plurality of types of vehicle body frames for motorcycles,
leading to a reduction in equipment cost. Moreover, the vehicle
body frame having a stable welding accuracy can be assembled by
welding the front and rear frame subassemblies positioned with a
good accuracy relative to each other. Additionally, the rear frame
subassembly is restrained while being positioned accurately
relative to the front frame subassembly by the pair of rear
positioning means and the pair of rear clamp means. Therefore, even
if a welding strain has been produced in the rear frame
subassembly, such strain can be corrected to assemble the vehicle
body frame for the motorcycle with a good accuracy.
[0009] According to a second aspect and feature of the present
invention, there is provided an apparatus for assembling a vehicle
body frame for a motorcycle by welding a front frame subassembly
having a head pipe at a front end thereof and a rear frame
subassembly to each other, comprising a pair of front positioning
means capable of positioning left and right rear portions of the
front frame subassembly, a front clamp means capable of clamping
the head pipe at the front end of the front frame subassembly, a
pair of rear positioning means capable of positioning left and
right rear portions of the rear frame subassembly, a pair of rear
clamp means capable of clamping left and right front portions of
the rear frame subassembly, a pair of front positioning drive means
for moving the front positioning means at least in a direction of a
Y-axis established in a widthwise direction of the vehicle body
frame, respectively, a front clamp drive means which is capable of
moving the front clamp means in directions of Z- and X-axes
established in vertical and longitudinal directions of the vehicle
body frame, and is capable of tilting the front clamp means about
an axis extending along the Y-axis, a pair of rear positioning
drive means capable of moving the rear positioning means in the
directions of X-, Y- and Z-axes, respectively, a pair of rear clamp
drive means capable of moving the rear clamp means in the
directions of X-, Y- and Z-axes, respectively, and a control unit
for controlling the operations of the drive means, so that the
front positioning means, the front clamp means, the rear
positioning means and the rear clamp means are brought into
positions previously determined depending on the type of the
vehicle body frame for the motorcycle, which is to be
assembled.
[0010] With the arrangement of the second feature, the pair of
front positioning means, the front clamp means, the pair of rear
positioning means and the pair of rear clamp means are moved
automatically to the positions corresponding to the vehicle body
frame in accordance with the change in type of the vehicle body
frame for the motorcycle, which is to be assembled. Therefore, the
process of the first feature can be carried out appropriately with
an enhanced efficiency of assembling of the vehicle body frame for
the motorcycle.
[0011] According to a third aspect and feature of the present
invention, in addition to the second feature, the front clamp means
includes a plurality of supporting pins capable of being fitted
into lower ends of a plurality of types of head pipes, a
pin-supporting plate for fixedly supporting one of the supporting
pins, while disposing the pin at a location below the head pipe, a
pushing member capable of being brought into engagement with an
upper end of the head pipe fitted at a lower end thereof over one
of the supporting pins, irrespective of the type of the head pipe,
thereby clamping the head pipe between the pushing member and the
one of the supporting pins, and a cylinder for providing pushing
force for pushing the head pipe from above to the pushing
member.
[0012] With the arrangement of the third feature, the head pipe can
be clamped between the supporting pin selected depending on the
head pipe to be retained and the pushing member corresponding to
any of the plurality of types of head pipes, thereby providing
general-purpose properties to accommodate the assembling of any of
the plurality of types of vehicle body frames for motorcycles,
leading to a reduction in equipment cost.
[0013] According to a fourth aspect and feature of the present
invention, in addition to the third feature, the apparatus further
includes an arm, at one end of which the pushing member is mounted,
the cylinder being disposed at a fixed position to have an axis
parallel to an axis of the head pipe and connected to the other end
of the arm through a connecting pin, a cam plate fixedly disposed
with a position thereof fixed relative to the cylinder, and having
a cam bore comprising a first bore portion extending in parallel to
the axis of the head pipe, and a second bore portion connected to
an upper end of the first bore portion and inclined in such a
direction that the second bore portion is more spaced apart from
the head pipe at an upper location, and a roller supported at an
intermediate portion of the arm and capable of being rolled within
the cam bore.
[0014] With the arrangement of the fourth feature, as the roller is
rolled within the cam bore in response to the expansion and
contraction of the cylinder, the arm is turned about the connecting
pin, while moving along with the connecting pin. In this case, a
lower portion of the cam bore is defined as the first bore portion
extending in parallel to the axis of the head pipe, and hence, when
the roller is rolled within the first bore portion, the arm and
thus the pushing member are also moved in parallel to the axis of
the head pipe. Therefore, when the upper end of the head pipe is
pushed by the pushing member, the movement of the pushing member
can be in a direction along the axis of the head pipe and thus, the
head pipe can be clamped stably and reliably between the supporting
pin and the pushing member in spite of the change in length of the
head pipe.
[0015] According to a fifth aspect and feature of the present
invention, in addition to the third or fourth feature, the
pin-supporting plate is disposed at a location below the head pipe
for turning movement about the axis parallel to the axis of the
head pipe; the supporting pins individually corresponding to the
plurality of types of head pipes are fixed to the pin-supporting
plate, so that the supporting pins are disposed at a plurality of
locations equally spaced apart from one another in a
circumferential direction of the pin-supporting plate; and the
apparatus further includes an index mechanism connected to the
pin-supporting plate to alternatively bring one of the plurality of
supporting pins to a position below the head pipe. With such
arrangement, in accordance with the change in type of the vehicle
body frame for the motorcycle, which is to be assembled, the
supporting pin corresponding to the head pipe can be selected
automatically and brought to the position below the head pipe,
leading to an enhanced assembling efficiency.
[0016] According to a sixth aspect and feature of the present
invention, in addition to the second feature, each of the front
positioning means and the rear positioning means includes a guide
wall which has a guide bore corresponding to a positioning bore
provided in a positioned member forming a portion of the front
frame subassembly or the rear frame subassembly to extend in a
widthwise direction of the vehicle body frame, the guide wall being
opposed to an outer side surface of the positioned member in a
position where the guide bore corresponds to the positioning bore,
a cylinder disposed coaxially with an axis of the guide bore on a
side of the guide wall opposite from the positioned member, a
plurality of movable rods which are capable of being fitted into
the guide bore for selective interposition as well as removable
insertion between the cylinder and the guide wall, each of the
movable rods being releasably connected at one end thereof to the
cylinder, and a plurality of types of positioning pins, each of
which is formed into such a shape as to be capable of fitting into
the positioning bore in any of a plurality of types of the
positioned members, the positioning pins being individually fixed
to the other ends of the movable rods.
[0017] With the arrangement of such sixth feature, one of the
plurality of movable rods, which has the positioning pin
corresponding to the type of the positioned member, is selected and
brought to between the cylinder and the guide wall and removably
fitted into the guide bore by connection with the cylinder. Thus,
the positioning pin corresponding to the positioning bore in the
positioned member can be fitted properly into the guide bore to
position a frame member, thereby providing general-purpose
properties to accommodate the assembling of any of the plurality of
types of vehicle body frames for motorcycles, leading to a
reduction in equipment cost.
[0018] According to a seventh aspect and feature of the present
invention, in addition to the sixth feature, the apparatus further
includes a rod-supporting plate disposed between the guide wall and
the cylinder for turning movement about an axis parallel to the
axis of the guide bore, the movable rods being disposed at the
locations equally spaced apart from one another in the
circumferential direction of the rod-supporting plate and retained
on the rod-supporting plate for sliding movement in a direction
parallel to the axis of the guide bore, and an index motor
connected to the rod-supporting plate for driving the
rod-supporting plate in turning movement, so that one of the
movable rods can be alternatively brought to a position between the
cylinder and the guide bore. With such arrangement, it is possible
to provide, in a simple structure, an arrangement designed so that
one of the plurality of types of positioning pins is selected in
correspondence to a frame member to be positioned, and is brought
to a position where it corresponds to the guide bore with a good
accuracy.
[0019] According to an eighth aspect and feature of the present
invention, in addition to the second feature, the rear clamp means
formed to clamp and retain a pipe-shaped frame member forming a
portion of the vehicle body frame and extending in the
substantially longitudinal direction of the vehicle body frame
includes a movable support which is capable of being moved in the
longitudinal, widthwise and vertical directions of the vehicle body
frame and is capable of being stopped at any position, a receiving
member which is formed into a substantially V-shape to open upwards
in a plane intersecting a lengthwise direction of the frame member,
and is fixed to the movable support so as to be disposed below the
frame member, a pushing member supported on the movable support for
swinging movement in such plane to sandwich the frame member
between the pushing member and the receiving member, and a drive
mechanism provided between the movable support and the pushing
member to drive the pushing member in swinging movement, each of
surfaces of the receiving member and the pushing member opposed to
the frame member being formed into such a shape as to be brought
into spherical contact with the frame member.
[0020] With the arrangement of such eighth feature, the movable
support is capable of being moved in the three-dimensional
directions and stopped at any position. Therefore, the frame member
can be clamped in spite of the change in outside diameter thereof
by fixedly disposing the substantially V-shaped receiving member
below the frame member at a location corresponding to the type of
the frame member to be clamped, and by swinging the pushing member
to sandwich the frame member between the pushing member and the
receiving member. Moreover, the receiving member and the pushing
member are brought into a spherical contact with the frame member
and hence, even if the angle formed by the lengthwise direction of
the frame member and a plane in which the receiving member and the
pushing member are disposed is varied to some extent, the frame
member can be reliably clamped between the receiving member and the
pushing member. Therefore, it is possible to provide
general-purpose properties to accommodate the assembling of any of
a plurality of types of vehicle body frames for motorcycles,
leading to a reduction in equipment cost.
[0021] The above and other objects, features and advantages of the
invention will become apparent from the following description of
the preferred embodiment taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1 to 9 show an embodiment of the present invention,
wherein
[0023] FIG. 1 is a perspective view of one example of a vehicle
body frame for a motorcycle;
[0024] FIG. 2 is a vertical sectional view of an assembling
apparatus, taken along a line 2-2 in FIG. 3;
[0025] FIG. 3 is a view taken in the direction of an arrow 3 in
FIG. 2, showing an upper half in an operated state and a lower half
in a non-operated state;
[0026] FIG. 4 is an enlarged sectional view taken along a line 4-4
in FIG. 3;
[0027] FIG. 5 is an enlarged view taken in the direction of an
arrow 5 in FIG. 3;
[0028] FIG. 6 is a sectional view taken along a line 6-6 in FIG.
5;
[0029] FIG. 7 is a sectional view taken along a line 7-7 in FIG.
5;
[0030] FIG. 8 is a sectional view taken along a line 8-8 in FIG.
7;
[0031] FIG. 9 is a sectional view taken along a line 9-9 in FIG.
6;
[0032] FIG. 10 is a sectional view taken along a line 10-10 in FIG.
6;
[0033] FIG. 11 is an enlarged sectional view taken along a line
11-11 in FIG. 3;
[0034] FIG. 12 is a view taken in the direction of an arrow 12 in
FIG. 11;
[0035] FIG. 13 is a sectional view taken along a line 13-13 in FIG.
11;
[0036] FIG. 14 is an enlarged sectional view taken along a line
14-14 in FIG. 11;
[0037] FIG. 15 is an enlarged sectional view taken along a line
15-15 in FIG. 11;
[0038] FIG. 16 is an enlarged view taken along a line 16-16 in FIG.
3;
[0039] FIG. 17 is a sectional view taken along a line 17-17 in FIG.
16;
[0040] FIG. 18 is a sectional view taken along a line 18-18 in FIG.
16; and
[0041] FIG. 19 is a block diagram showing the arrangement of a
control system for the assembling apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0042] The present invention will now be described by way of an
embodiment with reference to FIGS. 1 to 19. Referring first to FIG.
1, a vehicle body frame F for a motorcycle is comprised of a front
frame subassembly FF including a head pipe 25, a single main pipe
26 extending rearwards from the head pipe 25, and a pair of left
and right down-tubes 27, 27 connected at their front ends to the
head pipe 25 below the main pipe 26; and a rear frame subassembly
FR including sheet rails 28, 28 as a pair of left and right frame
members which are welded at their front ends to a rear portion of
the main pipe 26 and to which rear ends of the down-tubes 27, 27
are welded, respectively.
[0043] The main pipe 26 is formed so as to be integrally provided
with a rearward-inclined portion 26a extending rearwards and
downwards from the head pipe 25, and a descending portion 26c
connected to a rear end of the rearward-inclined portion 26a
through a curved portion 26b and extending downwards. The down-tube
27 is formed into a substantially U-shape with its upper portion
opened by a first tubular portion 27a declined rearwards from the
head pipe 25 and having a rear end formed substantially
horizontally, a second tubular portion 27b welded at its
substantially horizontal front end to a rear end of the first
tubular portion 27a and having a rear portion inclined rearwards
and upwards. A cross member 29 is mounted between the first tubular
portions 27a, 27a of the down-tubes 27, 27, and a cross member 30
is mounted between the second tubular portions 27b, 27b of the
down-tubes 27, 27.
[0044] A cross member 31 is connected at its central portion to a
rear end of the main pipe 26 and more specifically, to a lower end
of the descending portion 26c, and at its opposite ends to a pair
of left and right plate-shaped front support members 32, 32 as
members to be positioned. Each of the front support members 32, 32
is secured to an intermediate portion of each of the second tubular
portions 27b, 27b of the down-tubes 27, 27. Support tubes 33, 33
for swingably supporting front ends of swing arms supporting rear
wheels are secured to the front support members 32, 32, and
through-bores functioning as positioning bores 34, 34 for
determining the positions of the front support members 32, 32 in
assembling the vehicle body frame F are defined in the support
tubes 33, 33 with their opposite ends opened.
[0045] A pair of support tubes 35, 35 for supporting a power unit
(not shown) or the like are secured to each of the first tubular
portions 27a, 27a of the down-tubes 27, 27, and through-bores
functioning as positioning bores 36, 36 for determining the
positions of the down-tubes 27, 27 in assembling the vehicle body
frame F are defined, with their opposite ends opened in lower two,
for example, of the support tubes 35, 35.
[0046] In the rear frame subassembly FR, cross members 37, 38, 39
and 40 are mounted in the named order from the front side between
the sheet rails 28, 28, and plate-shaped rear support members 41,
41 as members to be positioned are secured to the sheet rails 28,
28 adjacent the rearmost cross member 40 to support tail lamps,
brake lamps or the like. Moreover, through-bores functioning as
positioning bores 42, 42 for determining the rear positions of the
sheet rails 28, 28 in assembling the vehicle body frame F are
provided, with their opposite ends opened, in the rear support
members 41, 41.
[0047] Such rear frame subassembly FR is assembled to the front
frame subassembly FF in such a manner that the sheet rails 28, 28
are welded at their front ends to an upper portion of the
descending portion 26c of the main pipe 26 of the front frame
subassembly FF, and at their intermediate portions to the rear
ends, i.e., upper ends of the second tubular portions 27b, 27b of
the down-tubes 27, 27 of the front frame subassembly FF, thereby
forming the vehicle body frame F for the motorcycle.
[0048] Referring to FIGS. 2 and 3, an assembling apparatus for
welding the front and rear frame subassemblies FF and FR to each
other to form the vehicle body frame F includes a base 44, so that
the front and rear frame subassemblies FF and FR are welded to each
other on the base 44.
[0049] Disposed on the base 44 are a head pipe retaining device 45
for retaining the head pipe 25 provided at the front end of the
front frame subassembly FF in a clamping manner, a pair of left and
right front support member-positioning devices 46, 46 for
positioning the front support members 32, 32 provided at the rear
portion of the front frame subassembly FF, a pair of left and right
down-tube positioning devices 47, 47 for positioning front portions
of the down-tubes 27, 27 provided on the front frame subassembly
FF, a pair of left and right rear support member-positioning
devices 48, 48 for positioning the rear support members 41, 41
provided at the rear ends of the rear frame subassembly FR, and a
pair of left and right sheet rail retaining devices 49, 49 for
retaining the front portions of the sheet rails 28, 28 provided on
the rear frame subassembly FR in a clamping manner.
[0050] The head pipe retaining device 45 is comprised of a front
clamp means 50 disposed on a movable support frame 62 for clamping
the head pipe 25 from above and below, and a front clamp drive
means 51 capable of moving the front clamp means 50 in a direction
of an X-axis which is a longitudinal direction of the vehicle body
frame F which is assembled on the base 44 and in a direction of a
Z-axis which is a vertical direction of the vehicle body frame F,
and tilting the front clamp means 50 forwards and rearwards.
[0051] Referring to FIGS. 4 to 8, the front clamp drive means 51
includes a rail 52 fixed on the base 44 to extend along the
direction of the X-axis, a carriage 53 movable on the rail 52, an
electric motor 54 fixedly disposed on the base 44 and having an
axis extending in the direction of the X-axis, a screw-feeding
mechanism 55 provided between the electric motor 54 and the
carriage 53 to convert the rotational force of the electric motor
54 into a linear driving force in the direction of the X-axis for
the carriage 53, a rail 56 provided on the carriage 53 to extend in
the direction of the Z-axis, i.e., in a vertical direction, an
elevator 57 which is capable of being lifted and lowered along the
rail 56, and has a bracket 57a for supporting a movable support
frame 62 with the front clamp means 50 disposed thereon for tilting
movement about the Y-axis that is a widthwise direction of the
vehicle body frame F, an electric motor 58 fixedly disposed on the
carriage 53 and having an axis extending along the Z-axis, a screw
feeding mechanism (not shown) provided between the electric motor
58 and the elevator 57 to convert the rotational force of the
electric motor 58 into a linear driving force in the direction of
the Z-axis for the elevator 57, a turnable frame 59 connected to a
lower portion of the elevator 57 for turning movement about an axis
extending along the Y-axis, an electric motor 60 fixedly disposed
on the turnable frame 59 and having an axis disposed in an X-Y
plane, arms 63, 63 extending downwards from the movable support
frame 62, and a screw feeding mechanism 61 provided between the
electric motor 60 and lower ends of arms 63, 63 to convert the
rotational force of the electric motor 60 into a reciprocally
turning force for the pair of arms 63, 63.
[0052] With such front clamp drive means 51, the movable support
framer 62 of the front clamp means 50 can be moved longitudinally
and vertically of the vehicle body frame F and moreover, can be
tilted about the axis provided by the Y-axis. Thus, according to a
change in type of the vehicle body frame F, to accommodate changes
in position of the head pipe 25 in the direction of the X-axis, in
height of the head pipe 25 from the base 44 and in inclination
angle of the head pipe 25, the front clamp means 50 can be moved to
any position corresponding to the position of the head pipe 25.
[0053] The movable support frame 62 includes a frame plate 64
connected at right angles to the arms 63, 63, extendable upwards
and downwards, at locations nearer to their upper portions, and
circular turnable plates 65, 65 connected to upper ends of the arms
63, 63. The turnable plates 65, 65 are carried at their central
portions on a bracket 57a of the elevator 57 through support shafts
66, 66 extending in the direction of the Y-axis.
[0054] Referring also to FIGS. 9 and 10,the front clamp means 50
includes a plurality of, e.g., four support pins 67A, 67B, 67C and
67D capable of being fitted into lower ends of a plurality of,
e.g., four types of the head pipes 25, respectively, a disk-shaped
pin-supporting plate 68 for fixedly supporting one of the support
pins 67A to 67D while disposing it at a location below the head
pipe 25, a pushing member 69 which has, at its tip end, an engage
portion 69a capable of being brought into engagement with the upper
end of the head pipe 25 fitted at its lower end over one of the
support pins 67A to 67D, irrespective of the type of the head pipe
25, and is capable of clamping the head pipe 25 between the pushing
member 69 and one of the support pins 67A to 67D, and a cylinder 70
for providing pushing force for pushing the head pipe 25 from above
to the pushing member 69.
[0055] The engage portion 69a is formed into a tapered shape on an
outer peripheral surface of a tip end of the pushing member 69, so
that it can be brought into insertion engagement with the upper end
of the head pipe 25 in spite of a variation in inside diameter of
the upper end of the head pipe 25. The pushing member 69 is
attached at one end of an arm 71.
[0056] On the other hand, the cylinder 70 is fixed to a lower
surface of the frame plate 64 in such a manner that an axis of the
cylinder 70 is parallel to the axis of the head pipe 25, when the
frame plate 64 of the movable support frame 62 has been brought
into an attitude perpendicular to the axis of the head pipe 25. A
connection member 72 connected to a tip end of a piston rod 70a
provided in the cylinder 70 is connected to the other end of the
arm 71 through a connecting pin 73 having an axis extending along
the Y-axis.
[0057] The other end of the arm 71 is slidably fitted between a
pair of cam plates 75, 75 secured to the frame plate 64 with a pair
of spacers 74, 74 interposed therebetween, and cam bores 76, 76 are
provided in the cam plates 75, 75 to correspond to each other.
[0058] Each of the cam bores 76 comprises a first bore portion 76a
extending in parallel to the axis of the head pipe 25, and a second
bore portion 76b connected to an upper end of the first bore
portion 76a and inclined in a direction such that it is more spaced
apart from the head pipe 25 at an upper location. Rollers 77, 77
are supported at an intermediate portion of the arm 71 above the
connecting pin 73 and capable of being rolled movement within the
cam bores 76, 76. Rollers 78, 78 are disposed below the rollers 77,
77 for rolling movement within the cam bores 76, 76 and supported
at opposite ends of the connecting pin 73.
[0059] As the rollers 77, 77; 78, 78 are rolled within the cam
bores 76, 76 by the expanding/contracting operation of the cylinder
70, the arm 71 is turned about the connecting pin 73, while being
moved along with the connecting pin 73, as shown by dashed lines in
FIG. 5. This causes the pushing member 69 mounted at one end of the
arm 71 to be operated so as to clamp the head pipe 25 between the
pushing member 69 and one of the support pins 67A to 67D.
[0060] The pin-supporting plate 68 is disposed at a location below
the head pipe 25 for turning movement about an axis parallel to the
axis of the head pipe 25. An index mechanism 80 is connected to the
pin-support plate 68 in order to individually correspond to a
plurality of types of the head pipes 25 and to alternatively bring
one of the support pins 67A to 67D fixed at a plurality of points
spaced apart from one another in a circumferential direction of the
pin-supporting plate 68 to a position below the head pipe 25.
[0061] The index mechanism 80 includes an index motor 81 fixed to
the frame plate 64, so that a turning force can be provided to the
pin-supporting plate 68, and a floating support base 82, which is
disposed between the pin-supporting plate 68 and the frame plate 64
for turnably supporting the pin-supporting plate 68. A bearing 83
is mounted between the pin-supporting plate 68 and the floating
support base 82.
[0062] The index motor 81 has an output shaft 81a passed through a
central portion of the floating support base 82 and spline-coupled
to a central portion of the pin-supporting plate 68. Thus, the
pin-supporting plate 68 is connected to the output shaft 81a of the
index motor 81 for relative movement in an axial direction of the
output shaft 81a and for non-relative rotation about the axis.
[0063] A coiled spring 84 is mounted between the floating support
base 82 and the frame plate 64 to surround the output shaft 81a, so
that the floating support base 82 and the pin-supporting plate 68
ate biased away from the frame plate 64 by a spring force of the
spring 84. On the other hand, limiting shafts 85 are relatively
slidably passed through the floating support base 82 at a plurality
of points (two points in the present embodiment) circumferentially
spaced apart from one another, and are fixed at their base ends to
the frame plate 64, and integrally provided at their tip ends with
limiting collars 85a capable of being brought into abutting
engagement with a surface of the floating support base 82 opposite
from the frame plate 64. The floating support base 82 is inhibited
by the limiting shafts 85 from being rotated about the axis of the
output shaft 81a, and ends of movement of the floating support base
82 and the pin-supporting plate 68 in a direction away from the
frame plate 64 are defined by the limiting shafts 85. A stopper 86
is fixed to the frame plate 64 and passed through the floating
support base 82 for relatively sliding movement in a direction
parallel to the axis of the output shaft 81a, so that ends of
movement of the floating support base 82 and the pin-supporting
plate 68 in a direction toward the frame plate 64 are defined by
the abutment of the pin-supporting plate 68 against the stopper
86.
[0064] The same number of guide tubes 88 as the number of the
supporting pins 67A to 67D fixed to the pin-supporting plate 68 are
provided on the pin-supporting plate 68 at locations equally spaced
apart from one another in a circumferential direction of the
pin-supporting plate 68. Guide pins 87 are fixed at their base ends
to the frame plate 64 and capable of being fitted at their tip ends
into the guide tubes 88, respectively. Each of the guide pins 87 is
relatively slidably passed through the floating support base 82 in
the axial direction.
[0065] Moreover, the length of each of the guide pins 87 is set
such that it is out of corresponding one of the guide tubes 88 of
the pin-supporting plate 68 in a state in which the floating
support base 82 and the pin-supporting plate 68 have been moved to
the maximum away from the frame plate 64, i.e., in a state in which
the limiting collars 85a of the limiting shafts 85 have been
brought into abutting engagement with the floating support base
82.
[0066] In such index mechanism 80, the pin-supporting plate 68 can
be turned by the operation of the index motor 81 in a state in
which no force is applied to the pin-supporting plate 68 from above
and the floating support base 82 and the pin-supporting plate 68
have been moved to the maximum away from the frame plate 64 by the
spring force of the spring 84. However, in a state in which the
pin-supporting plate 68 and the floating support base 82 have been
moved until the tip ends of the guide pins 87 has been fitted into
the guide tubes 88 respectively by application of a force to the
pin-supporting plate 68 from above, the pin-supporting plate 68
cannot be turned, whereby the relative positions of each of the
supporting pins 67A to 67D and the head pipe 25 in the
circumferential direction of the pin-supporting plate 68 can be
retained.
[0067] Referring particularly to FIGS. 2 and 3, the rear support
member-positioning device 48 is comprised of a rear positioning
means 90 for positioning the rear support member 41 provided on the
rear frame subassembly FR by utilizing the positioning bore 42 in
the rear support member 41, and a rear positioning drive means 91
capable of moving the rear positioning means 90 in the directions
of X-, Y- and Z-axes.
[0068] The rear positioning drive means 91 includes a rail 92 fixed
on the base 44 to extend in the direction of the X-axis, a carriage
93 movable on the rail 92, an electric motor 94 fixedly disposed on
the base 44 and having an axis extending in the direction of the
X-axis, a screw feeding mechanism (not shown) provided between the
electric motor 94 and the carriage 93 to convert the rotational
force of the electric motor 94 into a linear driving force for the
carriage 93 in the direction of the X-axis, a rail 95 provided on
the carriage 93 and extending in the direction of the Z-axis, i.e.,
in a vertical direction, an elevator 96 capable of being lifted and
lowered along the rail 95, an electric motor 97 fixedly disposed on
the rail 95 and having an axis extending along the Z-axis, a screw
feeding mechanism (not shown) provided between the electric motor
97 and the elevator 96 to convert the rotational force of the
electric motor 97 into a linear driving force for the elevator 96
in the direction of the Z-axis, a rail 98 extending in the
direction of the Y-axis and fixed to the elevator 96 to guide a
movable support 100 on which the rear positioning means 90 is
disposed, an electric motor 99 fixed to the rail 98 and having an
axis extending along the Y-axis, and a screw feeding mechanism (not
shown) provided between the electric motor 99 and the movable
support 100.
[0069] With such rear positioning drive means 91, the movable
support 100 for the rear positioning means 90 can be moved in the
directions of the X-, Y- and Z-axes, i.e., in the longitudinal,
widthwise and vertical directions of the vehicle body frame F.
Thus, to accommodate changes in position and height of the rear
support member 41 in the directions of X- and Y-axes according to a
change in type of the vehicle body frame F, the rear positioning
means 90 can be moved to any position corresponding to the position
of the rear support member 41.
[0070] Referring to FIGS. 11 to 13, the rear positioning means 90
includes a guide wall 102 which has a guide bore 101 corresponding
to the positioning bore 42 in the rear support member 41 and is
capable of being opposed to an outer side surface of the rear
support member 41 in a position where the guide bore 101
corresponds to the positioning bore 42, a cylinder 103 disposed
coaxially with the axis of the guide bore 101 on a side of the
guide wall 102 opposite from the rear support member 41, a
plurality of, e.g., three types of movable rods 104 which are
capable of being fitted into the guide bore 101 for selective
interposition as well as removable insertion between the cylinder
103 and the guide wall 102, each of the movable rods being
releasably connected at one end thereof to the cylinder 103, and a
plurality of, e.g., three types of positioning pins 105A, 105B and
105C which are formed into such shapes that they can be fitted into
the positioning bores 42 in the plurality of, e.g., three types of
rear support members 41, respectively, and are individually fixed
to the other ends of the movable rods 104.
[0071] A support arm 107 is secured to the movable support frame
100 to extend in the direction of the Y-axis, and includes the
guide wall 102 and a support wall 106 disposed to sandwich the rear
support members 41 between the support wall 106 and the guide wall
102. A receiving member 108 capable of clamping the rear support
members 41 between the receiving member 108 and the positioning
pins 105A, 105B and 105C is secured to the support wall 106, and
has a bottomed receiving bore 109 provided therein for reception of
the tip end of each of the positioning pins 105A, 105B and
105C.
[0072] A rod-supporting plate 110 is disposed between the guide
wall 102 and the cylinder 103 for turning movement about an axis
parallel to the axis of the guide bore 101. The rod-supporting
plate 110 is formed into a substantially Y-shape, for example and
includes a plurality of, e.g., three arm portions 110a at a
plurality of, e.g., three circumferentially equally spaced-apart
points, and the movable rods 104 are axially slidably retained on
rod-retaining portions 111 provided at tip ends of the arm portions
110a, respectively.
[0073] Referring to FIG. 14, each of the rod-retaining portions 111
has a slide bore 112 provided therein and having an axis parallel
to the guide bore 101 in the guide wall 102, so that each of the
movable rods 104 is slidably fitted in corresponding one of the
slide bores 112. A single guide groove 113 is provided on an outer
surface of each of the movable rods 104 to extend axially, and a
screw member 114 is fitted at its tip end in the guide groove 113
and threadedly inserted into each of the rod-retaining portions
111. Thus, each of the movable rods 104 is retained on
corresponding one of the rod-retaining portions 111 for sliding
movement in an axial direction, but for non-rotation about the
axis.
[0074] An annular groove 115 having a V-shape in cross section is
provided in an outer surface of each of the movable rods 104 at a
location close to the other end, i.e., at a location close to each
of the positioning pins 105A, 105B and 105C. Each of the
rod-retaining portions 111 has accommodating bores 116, 116
provided therein with their axes disposed on a diametrical line on
each of the movable rods 104. Accommodated in the accommodating
bores 116, 116 are a pair of spheres 117, 117 contacting with an
outer surface of each of the movable rods 104, and springs 118, 118
for biasing the spheres 117, 117 toward the movable rod 104, and
outer ends of the accommodating bores 116, 116 are closed by plugs
119, 119. Thus, when the movable rods 104 retract the positioning
pins 105A, 105B and 105C mounted at the other ends thereof away
from the receiving member 108, the spheres 117, 117 are brought
into resilient engagement in the annular groove 115, whereby the
positions of the movable rods 104 as retraction limits are
maintained moderately.
[0075] The cylinder 103 is mounted on a mounting plate 120 provided
on the support arm 107, and an index motor 121 is fixedly supported
on the mounting plate 120 with its axis parallel to the guide bore
101 and is connected to the central portion of the rod-supporting
plate 110 at equal distances to the movable rods 104. A bearing 122
is interposed between the rod-supporting plate 110 and the index
motor 121. Thus, the rod-supporting plate 110 is driven in turning
movement by the index motor 121 and turnably supported by the index
motor 121, so that one of the movable rods 104 is alternatively
brought to a position between the cylinder 103 and the guide bore
101 by the operation of the index motor 121.
[0076] The piston rod 121a included in the index motor 121 is
provided at its tip end with an engage portion 123 of a
substantially T-shape in a vertical plane. A substantially T-shaped
engage groove 124 is provided at one end of each of the movable
rods 104, as shown in FIG. 15, in such a manner that when the
movable rod 104 is turned in such a direction that it is disposed
in the position between the cylinder 103 and the guide bore 101,
the engage groove 124 is brought into engagement with the engage
portion 123, and when the movable rod 104 is turned in such a
direction that it leaves the position between the cylinder 103 and
the guide bore 101, the engage groove 124 is disengaged from the
engage portion 123.
[0077] Therefore, one of the movable rods 104 having the
positioning pins 105A, 105B and 105C, which is selected and brought
to the position between the cylinder 103 and the guide wall 102, is
connected to the cylinder 103 and thus, is releasably fitted into
the guide bore 101 in response to the expansion of the cylinder
103.
[0078] Referring particularly to FIGS. 2 and 3, the front support
member-positioning device 46 comprises a first front positioning
means 125 for positioning the front support member 32 included in
the front frame subassembly FF by utilizing the positioning bore 34
in the front support member 32, and a first front positioning drive
means 126 capable of moving the first front positioning means 125.
The first front positioning means 125 is formed basically in the
same manner as the rear positioning means 90 of the rear support
member-positioning device 48.
[0079] The first front positioning drive means 126 is formed to
move the first front positioning means 125 in the direction of at
least the Y-axis of the X-, Y- and Z-axes. In the present
embodiment, the first front positioning drive means 126 is formed
to be able to move the first front positioning means 125 in the
directions of the X- and Y-axes.
[0080] The reason why the first front positioning means 125 need
not be moved in the directions of the X- and Z-axes as in the above
way is that the positioning of the front support members 32, 32
included in the front frame subassembly FF is conducted by the
front support member-positioning device 46 at a first step in the
course of assembling of the vehicle body frame F, and that the
vehicle body frame F is assembled with the front support members
32, 32 utilized as reference positions.
[0081] The down-tube positioning device 47 comprises a second front
positioning means 127 for positioning the down-tube 27 included in
the front frame subassembly FF by utilizing the positioning bore 36
in the down-tube 27, and a second front positioning drive means 128
capable of moving the second front positioning means 127. The
second front positioning means 127 is formed basically in the same
manner as the rear positioning means 90 of the rear support
member-positioning device 48 and the first front positioning means
125 of the front support member-positioning device 46, and the
second front positioning drive means 128 is formed to move the
second front positioning means 127 in the directions of the X-, Y-
and Z-axes.
[0082] The sheet rail retaining device 49 is comprised of a rear
clamp means 130 for clamping the front portion of the sheet rail 28
included in the rear frame subassembly FR from above and below, and
a rear clamp drive means 131 capable of moving the rear clamp means
130 in the directions of the X-, Y- and Z-axes.
[0083] The rear clamp drive means 131 includes a rail 132 fixed to
the base 44 to extend in the direction of the X-axis, a carriage
133 movable on the rail 132, an electric motor 134 fixedly disposed
on the base 44 and having an axis extending in the direction of the
X-axis, a screw feeding mechanism (not shown) provided between the
electric motor 134 and the carriage 133 to convert the rotational
force of the electric motor 134 into a linear driving force for the
carriage 133 in the direction of the X-axis, a rail 135 mounted on
the carriage 133 to extend in the direction of the Z-axis, i.e., in
the vertical direction, an elevator 136 capable of being lifted and
lowered along the rail 135, an electric motor 137 fixedly disposed
on the rail 135 and having an axis extending along the Z-axis, a
screw feeding mechanism (not shown) provided between the electric
motor 137 and the elevator 136 to convert the rotational force of
the electric motor 137 into a linear driving force for the elevator
136 in the direction of the Z-axis, a rail 138 extending in the
direction of the Y-axis and fixed to the elevator 136 to guide a
movable support 140 on which the rear clamp means 130 is disposed,
an electric motor 139 fixed to the rail 138 and having an axis
extending along the Y-axis, and a screw feeding mechanism (not
shown) provided between the electric motor 139 and the movable
support 140.
[0084] With such rear clamping drive means 131, the movable support
140 for the rear clamp means 130 can be moved in the directions of
the X-, Y- and Z-axes, i.e., in the longitudinal, widthwise and
vertical directions of the vehicle body frame F. Thus, to
accommodate variations in position and height in the direction of
the sheet rail 28 in the X- and Y-axes in accordance with a change
in type of the vehicle body frame F, the rear clamp means 130 can
be moved to any position corresponding to the position of the sheet
rail 28.
[0085] Referring to FIGS. 16 to 18, the rear clamp means 130
includes the movable support 140 capable of being moved in the
longitudinal, widthwise and vertical directions of the vehicle body
frame F by the rear clamp drive means 131 and being stopped in any
position, a receiving member 141 formed into a substantially
V-shape to open upwards in a plane intersecting a lengthwise
direction of the sheet rail 28, and fixed to the movable support
140 so that it is disposed below the sheet rail 28, a pushing
member 142 supported on the movable support 140 for swinging
movement in such plane in such a manner that the sheet rail 28 is
interposed between the pushing member 142 and the receiving member
141, and a drive mechanism 143 provided between the movable support
140 and the pushing member 142 to drive the pushing member 142 in
swinging movement.
[0086] The pushing member 142 is turnably carried on the movable
support 140 through a support shaft 144 having an axis extending
along the X-axis. A surface 142a of the pushing member 142 opposed
to the sheet rail 28 is formed into such a shape that it is brought
into spherical contact with the sheet rail 28. A surface 141a of
the receiving member 141 opposed to the sheet rail 28 is also
formed into spherical contact with the sheet rail 28.
[0087] The drive mechanism 143 comprises a cylinder 146 which is
swingably supported on the movable support 140 by a pin 145
parallel to the support shaft 144 and has a piston rod 146a
connected to the pushing member 142 through a connecting pin 147
parallel to the support shaft 144 and the pin 145, so that the
pushing member 142 is turned about the support shaft 144 in
response to the expansion and contraction of the cylinder 146.
[0088] Referring to FIG. 19, the operations of the front clamp
drive means 51 in the head pipe retaining device 45, the first
front positioning drive means 126, 126 in the pair of left and
right front support member-positioning devices 46, 46, the second
front positioning drive means 128, 128 in the pair of left and
right down-tube positioning devices 47, 47, the rear positioning
drive means 91, 91 in the pair of left and right rear support
member-positioning devices 48, 48, and the rear clamp drive means
131, 131 in the pair of left and right sheet rail retaining device
49, 49 are controlled by a control unit 150.
[0089] The control unit 150 controls the operations of the drive
means 51, 91, 91, 126, 126, 128, 128 and 131, 131, so that the
front clamp means 50 in the head pipe retaining device 45, the
first front positioning means 125, 125 in the front support
member-positioning devices 46, 46, the second front positioning
means 127, 127 in the down-tube positioning devices 47, 47, the
rear positioning means 90, 90 in the rear support
member-positioning devices 48, 48, and the rear clamp means 130,
130 in the sheet rail retaining device 49, 49 are brought to
positions previously determined in accordance with the type of the
vehicle body frame F to be assembled for the motorcycle. For this
purpose, positional coordinates of various sites of the vehicle
body frame F intended to be assembled are previously determined in
a memory section included in the control unit 150 in correspondence
to the type of the vehicle body frame F intended to be assembled,
so that the operations of the drive means 51, 91, 91, 126, 126,
128, 128 and 131, 131 are controlled based on the positional
coordinates of the sites read from the memory section in accordance
with the type of the vehicle body frame F intended to be
assembled.
[0090] The operation of the embodiment will be described below. In
welding the front frame subassembly FF having the head pipe 25 at
the front end and the rear frame subassembly FR to each other to
assemble the vehicle body frame F for the motorcycle on the base
44, the following first to fifth steps are carried out:
[0091] At the first step, the front support member 32, 32 which are
left and right rear portions of the front frame subassembly FF are
positioned by the pair of first front positioning means 125, 125
movable at least in the direction of the Y-axis which is the
widthwise direction of the vehicle body frame F and in the present
embodiment, in the direction of the X-axis which is the
longitudinal direction of the vehicle body framer F and in the
direction of the Y-axis, and the down-tubes 27, 27 of the front
frame subassembly FF are positioned by the pair of second front
positioning means 127, 127 movable in the directions of the X- and
Y-axes and also in the direction of the Z-axis which is the
vertical direction of the vehicle body frame F. In this case, the
front clamp means 50 capable of being moved in the directions of
the Z- and X-axes and tilted about the axis extending along the
Y-axis has also been disposed in the position corresponding to the
head pipe 25, so that one of the supporting pins 67A to 67D
included in the front clamp means 50 has been fitted into the lower
end of the head pipe 25. Thus, in the front clamp means 50, a load
has been applied to the pin-supporting plate 68 to cause the guide
pins 87 to be fitted into the guide tubes 88, whereby the turned
position of the pin-supporting plate 68 has been fixed.
[0092] At the second step, the head pipe 25 is clamped and retained
from above and below by the front clamp means 50. Such first and
second steps ensure that the front frame subassembly FF is
positioned and supported.
[0093] Moreover, the pair of first front positioning means 125, 125
for positioning the left and right rear portions of the front frame
subassembly FF are movable at least in the widthwise direction of
the vehicle body frame F for the motorcycle, and the front clamp
means 50 for clamping the head pipe 25 at the front end of the
front frame subassembly FF is capable of being moved in the
longitudinal and vertical directions of the vehicle body frame F
for the motorcycle and tilted in the longitudinal direction.
Therefore, in a state in which the left and right rear portions of
the front frame subassembly FF have been positioned by the first
front positioning means 125, 125, the changes in position and
attitude of the head pipe 25 depending on the change in type of the
front frame subassembly FF can be covered by the movement of the
front clamp means 50 in the longitudinal and vertical directions
and the tilting of the front clamp means 50 about the Y-axis,
whereby the front frame subassembly FF can be positioned and
supported with a good accuracy. In addition, the down-tubes 27, 27
of the front frame subassembly FF are positioned by the pair of
second front positioning means 127, 127 movable in the directions
of X-, Y- and Z-axes and hence, the positioning and supporting
accuracy of the front frame subassembly FF can be further
enhanced.
[0094] At the third step, the left and right rear portions of the
rear frame subassembly FR are positioned by the pair of rear
positioning means 90, 90 movable in the directions of X-, Y- and
Z-axes. At the fourth step, the left and right front portions of
the rear frame subassembly FR are clamped by the pair of rear clamp
means 130,130 movable in the directions of X-, Y- and Z-axes.
[0095] As described above, the pair of rear positioning means 90,
90 for positioning the left and right rear portions of the rear
frame subassembly FR are movable in the longitudinal, widthwise and
vertical directions of the vehicle body frame F for the motorcycle,
and the pair of rear clamp means 130,130 for clamping the left and
right front portions of the rear frame subassembly FR are movable
in the longitudinal, widthwise and vertical directions of the
vehicle body frame F for the motorcycle. Thus, even if the type of
the rear frame subassembly FR is changed the rear frame subassembly
FR can be positioned and supported with a good accuracy relative to
the front frame subassembly FF, thereby providing general-purpose
properties to accommodate the assembling of any of a plurality of
types of vehicle body frames F for motorcycles, thus reducing the
equipment cost.
[0096] At the fifth step, the front and rear frame subassemblies FF
and FR positioned relative to each other are welded to each other
to assemble the vehicle body frame F. In this case, the vehicle
body frame F can be assembled with a stable welding accuracy by
welding the front and rear frame subassemblies FF and FR positioned
with a good accuracy relative to each other. In addition, the rear
frame subassembly FR is restrained, while being positioned with a
good accuracy relative to the front frame subassembly FF, by the
pair of rear positioning means 90, 90 and the pair of rear clamp
means 130, 130. Therefore, even if a welding strain has been
produced in the rear frame subassembly FR, such strain can be
corrected to assemble the vehicle body frame F for the motorcycle
with a good accuracy.
[0097] It should be noted here that the operations of the pair of
front positioning drive means 126, 126 for moving the pair of the
first front positioning means 125, 125 in the directions of X- and
Y-axes, the operations of the pair of the second front positioning
drive means 128, 128 for moving the pair of second front
positioning means 127, 127 in the directions of the X-, Y- and
X-axes, the operations of the front clamp drive means 51 for moving
the front clamp means 50 in the directions of the Z- and X-axes and
tilting the front clamp means 50 about the axis extending along the
Y-axis, the operations of the pair of rear positioning drive means
91, 91 for moving the pair of rear positioning means 90, 90 in the
directions of the X-, Y- and Z-axes, and the operations of the pair
of rear clamp drive means 131, 131 for moving the pair of rear
clamp means 130, 130 in the directions of the X-, Y- and Z-axes are
controlled by the control unit 150, so that the first front
positioning means 125, 125, the second front positioning means 128,
128, the front clamp means 50, the rear positioning means 90, 90
and the rear clamp means 130, 130 are brought to the positions
previously determined depending on the type of the vehicle body
frame F for the motorcycle, which is to be assembled.
[0098] Therefore, in accordance with the change in type of the
vehicle body frame F for the motorcycle, which is to be assembled,
the first front positioning means 125, 125, the second front
positioning means 128, 128, the front clamp means 50, the rear
positioning means 90, 90 and the rear clamp means 130, 130 are
brought automatically to the positions corresponding to the vehicle
body frame F, and thus, the efficiency of assembling of the vehicle
body frame F for the motorcycle can be enhanced.
[0099] The head pipe retaining device 45 for clamping and retaining
the head pipe 25 provided at the front end of the front frame
subassembly FF includes the plurality of supporting pins 67A, 67B,
67C and 67D capable of being fitted into the lower ends of the
plurality of types of the head pipes 25, respectively, the
pin-supporting plate 68 for fixedly supporting one of the
supporting pins 67A, 67B, 67C and 67D, while disposing it in the
position below the head pipe 25, the pushing member 69 which can be
brought into engagement with the upper end of the head pipe 25
fitted at its lower end over one of the supporting pins 67A, 67B,
67C and 67D, irrespective of the type of the head pipe 25, and is
capable of clamping the head pipe 25 between the pushing member 69
itself and one of the supporting pins 67A, 67B, 67C and 67D, and
the cylinder 70 for providing, to the pushing member 69, the
pushing force for pushing the head pipe 25 from above.
[0100] Therefore, any of the plurality of types of the head pipes
25 can be clamped between one of the supporting pins 67A, 67B, 67C
and 67D selected depending on the type of the head pipe 25 to be
retained and the pushing member 69 corresponding to the type of the
head pipe 25, and thus, the general-purpose properties can be
provided to the head pipe retaining device 45 to accommodate the
assembling of any of the plurality of types of vehicle body frames
F for motorcycles, thereby providing a reduction in equipment
cost.
[0101] In addition, the piston rod 70a of the cylinder 70 disposed
in the fixed position and having the axis parallel to the axis of
the head pipe 25 is connected to the other end of the arm 71 having
the pushing member 69 mounted at one end thereof through the
connecting pin 73. The cam plates 75, 75 are fixedly disposed on
the movable support frame 62 with its position fixed relative to
the cylinder 70 and have the cam bores 76, 76 each comprising the
first bore portion 76a extending in parallel to the axis of the
head pipe 25 and the second bore portion 76b connected to the upper
end of the first bore portion 76a and inclined in the direction
such that it is more spaced apart from the head pipe 25 at the
upper location. The rollers 77, 77 capable of being rolled within
the cam bores 76, 76 are supported at the intermediate portion of
the arm 71.
[0102] Therefore, as the rollers 77, 77 are rolled within the cam
bores 76, 76 in response to the expansion and contraction of the
cylinder 70, the arm 71 is turned about the connecting pin 73,
while being moved along with the connecting pin 73. In this case,
the lower portion of the cam bore 76 is defined as the first bore
portion 76a extending in parallel to the axis of the head pipe 25,
and when the roller 77 is rolled within the first bore portion 76a,
the arm 71 and thus the pushing member 69 are also moved in
parallel to the axis of the head pipe 25. Therefore, when the upper
end of the head pipe 25 is pushed by the pushing member 69, the
movement of the pushing member 69 can be in the direction along the
axis of the head pipe 25 and hence, the head pipe 25 can be clamped
stably and reliably between one of the supporting pins 67A, 67B,
67C and 67D and the pushing member 69, irrespective of a variation
in length of the head pipe 25.
[0103] Moreover, the supporting pins 67A, 67B, 67C and 67D
individually corresponding to the plurality of types of the head
pipes 25 are fixed to the pin-supporting plate 68 disposed at the
location below the head pipe 25 for turning movement about the axis
parallel to the axis of the head pipe 25, so that they are disposed
at the plurality of locations equally spaced apart from one another
in the circumferential direction of the pin-supporting plate 68,
and the index mechanism 80 for alternatively bringing one of the
supporting pins 67A, 67B, 67C and 67D to the position below the
head pipe 25 is connected to the pin-supporting plate 68.
Therefore, one of the supporting pins 67A, 67B, 67C and 67D
corresponding to the head pipe 25 can be selected automatically in
accordance with the change in type of the vehicle body frame F for
the motorcycle, to be assembled, and brought below the head pipe
25, leading to an enhanced assembling efficiency.
[0104] The sheet rail-retaining device 49 for clamping and
retaining the pipe-shaped sheet rail 28 forming a portion of the
vehicle body frame F for the motorcycle and extending in the
substantially longitudinal direction of the vehicle body frame F
includes the movable support 140 which is capable of being moved in
the longitudinal, widthwise and vertical directions of the vehicle
body frame F and stopped at any position, the receiving member 141
formed into the substantially V-shape to open upwards in the plane
intersecting the direction of the lengthwise direction of the sheet
rail 28 and fixed to the movable support 140 so as to be disposed
below the sheet rail 28, the pushing member 142 supported on the
movable support 140 for swinging movement within such plane to
sandwich the sheet rail 28 between the pushing member 142 and the
receiving member 141, and the drive mechanism 143 provided between
the movable support 140 and the pushing member 142 to drive the
pushing member 142 in swinging movement.
[0105] Therefore, by fixedly disposing the receiving member 141
below the sheet rail 28 at a location corresponding to the type of
the sheet rail 28 to be clamped, and swinging the pushing member
142 to sandwich the sheet rail 28 between the pushing member 142
and the receiving member 141, the sheet rail 28 can be clamped
irrespective of a variation in outside diameter of the sheet rail
28.
[0106] The surfaces of the receiving member 141 and the pushing
member 142 opposed to the sheet rail 28 are formed into such shapes
that they are brought into spherical contact with the sheet rail 28
and hence, even if the angle formed by the lengthwise direction of
the sheet rail 28 and the plane in which the receiving member 141
and the pushing member 142 are disposed is changed to some extent,
the sheet rail 28 can be reliably clamped between the receiving
member 141 and the pushing member 142.
[0107] Therefore, it is possible to provide the general-purpose
properties to the seat rail-retaining device 49 to accommodate the
assembling of any of the plurality of types of vehicle body frames
F for motorcycles, thereby reducing the equipment cost.
[0108] The rear support member-positioning device 48 for
positioning the rear support member 41 forming a portion of the
vehicle body frame F for the motorcycle and having the positioning
bore 42 extending in the widthwise direction of the vehicle body
frame F by utilizing the positioning bore 42 includes the guide
wall 102 having the guide bore 101 and capable of being opposed to
the outer side surface of the rear support member 41 in the
position where the guide bore 101 corresponds to the positioning
bore 42, the cylinder 103 disposed coaxially with the axis of the
guide bore 101 on the side of the guide wall 102 opposite from the
rear support member 41, the plurality of movable rods 104 which are
capable of being fitted into the guide bore 101 for selective
interposition as well as removable insertion between the cylinder
103 and the guide wall 102, each of the movable rods being
releasably connected at one end thereof to the cylinder 103, and
the plurality of types of positioning pins 105A, 105B and 105C
which are formed into such shapes that they can be fitted into the
positioning bores 42 in the plurality of types of rear support
members 41, respectively, and are individually fixed to the other
ends of the movable rods 104.
[0109] Therefore, one of the plurality of movable rods 104, which
has the positioning pin 105A, 105B, 105C corresponding to the rear
support member 41 to be positioned, is selected and brought to the
position between the cylinder 103 and the guide wall 102 and
removably fitted into the guide bore 101 by connection with the
cylinder 103, and the positioning pin corresponding to the
positioning bore 42 in the rear support member 41 to be positioned
can be fitted properly into the guide bore 101 to position the rear
support member 41. Thus, it is possible to provide the
general-purpose properties to the rear support member-positioning
device 48 to accommodate the assembling of any of the plurality of
types of vehicle body frames for motorcycles, thereby providing a
reduction in equipment cost.
[0110] Further, the movable rods 104 are disposed at locations
equally spaced apart from one another in the circumferential
direction of the rod-supporting plate 110 disposed between the
guide wall 102 and the cylinder 103 for turning movement about the
axis parallel to the axis of the guide bore 101, and are retained
on the rod-supporting plate 110 for sliding movement in the
direction parallel to the axis of the guide bore 101. The index
motor 121 is connected to the rod-supporting plate 110 for driving
the rod-supporting plate 110 in turning movement, so that one of
the movable rods 104 can be alternatively brought to a position
between the cylinder 103 and the guide bore 101.
[0111] Therefore, it is possible to provide, in a simple structure,
an arrangement designed so that one of the plurality of types of
positioning pins 105A, 105B and 105C can be selected in
correspondence to the rear support member 41 to be positioned and
can be brought to a position where it corresponds to the guide bore
101 with a good accuracy.
[0112] Further, the front support member-positioning device 46 for
positioning the front support member 32 forming a portion of the
vehicle body frame F for the motorcycle and having the positioning
bore 34 extending in the widthwise direction of the vehicle body
frame F by utilizing the positioning bore 34, as well as the
down-tube positioning device 47 for positioning the down-tube 27
forming a portion of the vehicle body frame F for the motorcycle
and having the positioning bore 36 extending in the widthwise
direction of the vehicle body frame F by utilizing the positioning
bore 36 is formed in a similar manner to the rear support
member-positioning device 48. Thus, it is possible to provide the
general-purpose properties to the front support member-positioning
device 46 and the down-tube positioning device 47 to accommodate
the assembling of any of the plurality of types of vehicle body
frames F for motorcycles, thereby providing a reduction in
equipment cost.
[0113] Although the embodiment of the present invention has been
described in detail, it will be understood that the present
invention is not limited to the above-described embodiment, and
various modifications in design may be made without departing from
the spirit and scope of the invention defined in claims.
[0114] For example, in the embodiment, the front support members
32, 32 which are the left and right rear portions of the front
frame subassembly FF are positioned by the pair of first front
positioning means 125, 125, and the down-tubes 27, 27 of the front
frame subassembly FF are positioned by the pair of second front
positioning means 127, 127 at the first step. However, the
positioning of the down-tubes 27, 27 of the front frame subassembly
FF by the pair of second front positioning means 127, 127 may be
omitted, and at least the left and right rear portions of the front
frame subassembly FF may be positioned.
* * * * *