Note: Descriptions are shown in the official language in which they were submitted.
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END MODULE ASSEMBLY FOR INSTALLATION ON A VEHICLE AND
METHOD FOR MAKING THE SAME
Field of the Invention
The present invention relates to an end module assembly for installation on
either a front or rear end of a vehicle and a method for making the same.
Background of the Invention
In the typical method of assembling a motor vehicle, the vehicle is moved
down an assembly line and components are individually fastened to the vehicle.
In
the front end of the vehicle, a radiator support structure is fastened to the
vehicle
body. Each of the components associated with the vehicle front end are then
fastened
individually to the support structure. In particular, external components,
such as head
lamps, fog lamps, and the grill, and the front end fascia are fastened to the
support
structure individually. Fastening components in such a manner oftentimes
causes the
external components and the exterior fascia to be misaligned with respect to
one
another due to the potential error margins associated with mounting each part
individually. The sum of these error margins can cause component misalignment
and
poor vehicle aesthetics. To achieve proper component alignment, each external
component must not only be aligned properly with respect to the fascia, but
also with
every other external component. Correcting these errors consumes time,
increases
labor costs, and decreases overall manufacturing efficiency.
U.S. Patent Nos. 5,123,695 and 5,358,304 disclose assemblies in which the
front end fascia and the external visible components associated with the front
end are
pre-assembled to each other and optionally to an integrating structure or
carrier panel.
This arrangement allows the entire assembly to be mounted directly on the
vehicle.
The assembly disclosed in these patents, however, does not obviate the
problems
associated with the method described above because the fascia and the external
visible
components are still being mounted individually and then the assembly is
mounted to
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the vehicle. Due to the individual mounting of the fixtures, the same
component
misalignment problems will occur.
Summary of the Invention
It is therefore an object of the present invention to provide an end module
assembly with superior component alignment between the fascia and external
components, thereby obviating the need for reorienting the components after
installation or accepting any misalignment because there are no adjustment
provisions.
In order to achieve the object of the present invention, there is provided an
end
module assembly for installation on a motor vehicle. The assembly comprises an
exterior fascia configured to comprise a portion of a vehicle body when the
assembly
is subsequently installed on the vehicle. An external visible component is
configured
to be positioned in a predetermined orientation with respect to the fascia
with surfaces
of the component facing exteriorly of the fascia. The fascia has a position
controlling
portion. The external visible component is positioned relative to the fascia
such that
the portion guides the external component into the predetermined orientation
and
supports the component thereat, thereby allowing the assembly to be installed
on the
motor vehicle without requiring reorientation of the component.
According to another aspect of the present invention, there is provided a
method for assembling an end module assembly for installation on a motor
vehicle.
The method comprises providing an exterior fascia configured to comprise a
portion
of the vehicle body when the assembly is subsequently installed on the motor
vehicle.
An external visible component is configured to be positioned in a
predetermined
orientation with respect to the fascia with surfaces thereof facing exteriorly
of the
fascia. Both the external component and the fascia are positioned in an
external
assembling fixture. The assembling fixture provides fixed surfaces positioned
and
configured to engage the exteriorly facing surfaces of the external visible
component
and exteriorly facing surfaces of the fascia so as to support the fascia in
the
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predetermined orientation with respect to the fascia. The external component
and the
fascia are thereafter secured in fixed relation while in the assembling
fixture so as to
fix the component in the predetermined orientation thereof, thereby allowing
the
assembly to be installed on the vehicle without requiring reorientation of the
external
visible component.
According to yet another aspect of the present invention, there is provided
another method for assembling an end module assembly for installation on a
motor
vehicle. The method comprises providing an exterior fascia configured to
comprise a
portion of a vehicle body when the assembly is subsequently installed on the
motor
vehicle. An external visible component is configured to be positioned in a
predetermined orientation with respect to the fascia with surfaces of the
external
visible component facing exteriorly of the fascia. The component and the
fascia are
positioned relative to one another such that position controlling portions of
the fascia
guide the component into the predetermined orientation with respect to the
fascia and
support the fixture thereat, thereby allowing the module assembly to be
subsequently
installed on the motor vehicle without requiring reorientation of the
component.
An end module assembly constructed in accordance with the principles of the
present invention provides superior component alignment in comparison to
assembling in which the component and the fascia are mounted individually to
an
integrating structure. Specifically, the present invention provides optimal
part-to-part
fit and accurately positions all end module components. The components may
include, but are not limited to, lamps, the grill, and decorative trim. It
should be
appreciated that the principles of the present invention may also be applied
to rear end
module assemblies as well as front end module assemblies.
Another aspect of the present invention relates to a loading fixture for
installing a front end module assembly onto a motor vehicle having a body and
a
frame movable relative to one another. The module assembly comprises an
exterior
fascia, external components, and bumper beam supporting structure loosely
supporting the bumper beam. The fixture comprises a first lifting fixture
constructed
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and arranged to engage the module assembly so as to lift and subsequently move
the
module assembly into a module installation position wherein the module
assembly
can be installed on the vehicle with the fascia comprising a portion of the
vehicle
body. A second lifting fixture is constructed and arranged to engage and lift
the
bumper beam relative to the bumper beam supporting structure such that, when
the
first lifting fixture subsequently moves the module assembly into the
installation
position thereof, the second li$ing fixture supports the bumper beam in a
bumper
beam installation position for subsequent attachment to the vehicle frame.
Brief Description of the Drawings
Exemplary embodiments of the invention will now be described in
conjunction with the following drawings wherein like numerals represent like
elements, and wherein:
FIG. 1 is an exploded view of a front end module assembly for a framed
vehicle with integral radiator support structure in accordance with a first
embodiment
of the present invention;
FIG. 2 is a perspective view of the embodiment shown in FIG. 1;
FIG. 3 is an exploded view of a front end module assembly for a framed
vehicle without an integral radiator support structure in accordance with a
second
embodiment of the present invention;
FIG. 4 is a perspective view of the embodiment shown in FIG. 3;
FIG. 5 is an exploded view of a front end module assembly for a unibody
vehicle in accordance with a third embodiment of the present invention;
FIG. 6 is a perspective view of the embodiment shown in FIG. 5;
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FIG. 7 is a perspective view of a front end module loading fixture, disposed
in
operating relation with a front end module assembly embodying the principles
of the
present invention; and
FIG. 8 is an enlarged sectional view taken along the line 8-8 in FIG. 7;
FIG. 9 is a cross-sectional view taken through a front end module assembly
and an external assembly fixture wherein the assembly fixture orients the
external
components and the fascia relative to one another;
FIG. 10 is a perspective view of a front end module assembly taken from the
front;
FIG. 11 is a sectional view with the assembly positioned in an assembling
fixture taken along lines 11-11 of FIG. 10 and through the fixture.
Detailed Description of the Invention
FIGS. 1 and 2 show a front end module assembly, generally indicated at 10,
for a framed motor vehicle constructed in accordance with the principles of
the
present invention. For simplicity of explanation, the module assembly 10 may
be
considered to comprise two groups of parts: a forward group, or fascia sub-
module,
generally illustrated at 12; and a rear group, or cooling sub-module,
generally
illustrated at 16.
The forward group 12, includes a molded plastic fascia, generally depicted at
18. Typically, the fascia 18 is relatively flexible without a great deal of
structural
rigidity. The forward group 12 includes a number of external visible
components and
other front end-associated parts that are secured to the assembly 10 by
conventional
fasteners in fixed relation with respect to the fascia 18. The external
components
comprise components which are to be positioned in a predetermined orientation
with
respect to the fascia 18 with surfaces thereof facing exteriorly of the fascia
18. These
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external components include, but are not limited to, an air dam 20, fog lamps
22, head
lamps 24, and a gri1126.
The air dam 20 is fixed to the bottom of the fascia 18, extending
approximately the length of the fascia 18 in the cross-car direction. A pair
of
auxiliary or fog lamps 22 are mounted in fog lamp receiving openings defined
by
holes 23 disposed in laterally spaced relation in the front of the fascia 18.
The head
lamps 24 are laterally spaced and mounted in head lamp receiving openings
defined
by fascia panel recesses 25 molded near the lateral or cross-car ends of the
fascia 18
above the holes 23 for fog lamps 22. The fog lamps 22 form a snap-fit
connection
with holes 23. The recesses 25 have a plurality of holes 17 for receiving
various bolts
and wiring components 27 that enable the headlamps 24 to be loosely secured in
proper centered position relative to the recesses 25 in the fascia 18.
A pair of hood bumpers 30 are disposed near the opposite ends of the upper
surface of an upper elongate horizontal portion 29 of the fascia 18. A hood
latch
assembly 28 is fixed to the forward surface of the upper horizontal portion 29
towards
the center of the fascia 18. More particularly, latch assembly 28 has a
downwardly
depending flange 31 which is fastened via bolts to the forward face of
horizontal
portion 29. The latch assembly 28 further includes an upper flange portion 37
extending rearwardly from flange portion 31 and disposed at right angles to
flange
portion 31. The flange portion 37 is fixed by appropriate fasteners to an
upwardly
facing surface of horizontal portion 29. The gril126 is fixed to the fascia 18
by
appropriate fasteners at a horizontally extending opening 21 disposed at the
upper
middle area of the front of the fascia 18.
A steel bumper beam 32 having a "C"-shaped cross section defining opening
47 is disposed across the width of the module assembly 10. An elongated foam
block
34 is hollowed out at its rear side and receives in fixed relation the
forward, lower,
and upper portions of the bumper beam 32 with the opening 47 of the C-section
facing rearwardly. The rearwardly facing surfaces of the bumper beam 32 above
and
below the C-opening are provided with a plurality of fasteners in the form of
nuts 33
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at the opposite end portions of the bumper beam 32. The nuts 33 are preferably
welded to the bumper beam. The rearward facing surface of bumper beam 32 also
has a pair of laterally spaced hook shaped beam catches 45 which are used in
mounting the bumper beam 32 on a vehicle frame as will be described. A pair of
bumper beam supporting structures in the form of fascia support brackets 36,
38 are
secured to the back of the fascia 18. Base portions 41, 43 of the respective
fascia
support bracket 36, 38 are secured in fixed relation with an inside base 19 of
the
fascia 18 by appropriate fasteners. Fasteners are also used to fix tabs 37
rising from
each of a pair of upper legs 39 of fascia support brackets 36, 38 to the rear
surface of a
middle horizontal portion 15 of the fascia 18.
The brackets 36, 38 loosely capture the bumper beam 32 within leg portions
39 so as to position the bumper beam 32 within the lower cavity formed above
the
inside base 19 of the fascia 18. A temperature sensor 40 and a horn assembly
42 are
secured to the base or bottom leg 41 of one of the fascia support brackets 36,
while an
air bag sensor 44 is secured to the base 43 of the other fascia support
bracket 38.
Support brackets 36,38 each have a large aperture 35 which can receive
therethrough
a plurality of bolts that can be used to secured the bumper beam 32 (via nuts
33) to the
vehicle frame front rail brackets 73 after the module assembly 10 is secured
to the
front end of the vehicle as will be described.
The bumper beam 32 is not connected to or supported by any other
components within the module assembly 10, as it must eventually be connected
during final assembly with front rail brackets 73 of the vehicle frame.
Conventional
framed vehicle system dynamics allow relative movement between the chassis
system
(such as the vehicle frame, bumper beam, etc.) and the body system (fascia,
body
panels, etc) during vehicle operation. Thus, the bumper beam 32 merely rests
between legs 39 of the brackets 36 and 38 when the module is shipped for
vehicle
assembly. After assembly to the vehicle, the bumper beam 32 is fixed to front
rail
brackets 73 in spaced relation to the fascia 18 to permit slight movement
between
fascia 18 and beam 32 during vehicle operation. The beam 32, when fixed to
brackets
73 in the assembled vehicle is hidden by the fascia 18.
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The rear group 16 includes a component integrating structure in the form of a
radiator support structure 48, generally extending the full width of the
module
assembly 10. The rear group 16 further comprises a cooling module 50,
including but
not limited to a radiator, condenser, transmission oil cooler, and fan shroud
56. A
plurality (preferably three) of upwardly extending tabs 51 are fixed to and
extend
upwardly from an upper portion of cooling module 50. The outer two tabs 51
have
forwardly extending portions provided with holes 381 which are used for
lifting the
module assembly 10 during installation on the front end of a vehicle.
A plurality (preferably three) of downwardly extending tabs are fixed to and
extend downwardly from a lower portion of cooling module 50. A radiator center
support "V" bracket 52 is fixed on the forward face of the cooling module 50
at a
central upper tab 51 and two of the lower outer tabs 53. The cooling module 50
has
laterally outwardly extending fascia mounting brackets 60 which are supported
and
mounted to the uppermost surface of the upper legs 39 of the associated fascia
support
brackets 36 and 38.
The radiator support structure 48 has an opening 55 through which the cooling
module 50 extends rearwardly. The radiator support structure 48 further
includes a
lower wall 75 beneath opening 55 and to which fasteners secure tabs 53 of the
cooling
module 50. A pair of tabs 59 are appended to the lower edge of the radiator
support
48, and are disposed slightly inwardly to the lateral ends of the support 48.
The tabs
59 attach to radiator support frame mounts 67, which are fixed to the vehicle
frame
63, through holes 61. Fender mounting brackets 54 each have elongated openings
57
disposed in an elongated leg portion 66 of the mounts 54. The elongated leg
portions
66 are sandwiched between the tabs 59 of radiator support structure 48 and
resilient
isolator mounting structures 67 of the vehicle frame 63. Fasteners pass
through
openings 68 in the tabs 59, through the elongated openings 57 in the fender
mounting
brackets 54, and through holes 61 in the isolator mounting structures 67. As a
result,
the radiator support structure 48 can be fixed to the vehicle frame 63, with
isolator
mounts 67 providing for slight relative movement between the module 10 and
frame
63. Each fender mounting bracket 54 further includes a truncated leg 70
disposed at a
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right angle to elongated leg 66. Truncated legs 70 facilitate securement of
fenders 65
to the vehicle frame 63. Each fender 65 is provided with a mounting tab 71
which has
openings 72 that can be used to fasten the fenders 65 to opposite sides of the
radiator
support structure 48 at holes 64.
As shown, radiator support structure 48 also includes a plurality of holes 90
that receive the bolts 27 of headlamps 24 to rigidly fix the headlamps to the
radiator
support structure 48 and in proper centered orientation to recesses 25.
Radiator
support structure 48 also has holes 57 for receiving wiring from a wiring
harness 80
that provides power to headlamps 24. The wiring harness 80 also provides power
to
other electrical components of the front end module 10, such as fog lamps 22.
Fixed
to the front end of vehicle frame 63 are the previously described pair of
front frame
brackets 73. During assembly, bumper beam 32 is connected to front frame
brackets
73 via appropriate bolts being fastened through nuts 33 on the bumper beam 32.
It should be appreciated that the frame 63, fender 65, front frame brackets 73
do not form part of module 10, but are particularly constructed and arranged
to
accommodate assembly of module 10 as a unit thereon.
To ensure proper orientation between the external components and the fascia
18 prior to installation of the vehicle, it is important to properly orient
the components
during the assembly with respect to one fixed reference point or template.
Disclosed
hereinbelow are two methods which will achieve such proper orientation.
In one method of the present invention, an external assembling fixture,
generally indicated at 500 in FIG. 9, functions as the template. The
assembling
fixture 500 provides fixed surfaces including fascia supporting surfaces 502,
grill
supporting surfaces 504, and head lamp supporting surfaces 506. These fixed
surfaces 502, 504, 506 are positioned and configured to engage exteriorly
facing
surfaces 508, 510 of the external visible components (i.e., the head lamps 24
and grill
26) and exteriorly facing surfaces 512 of the fascia 18 so as to support the
external
components in their predetermined orientations with respect to the fascia 18.
Thus,
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the surfaces of the assembling fixture 500 control the relative positioning
between the
fascia 18 and the external components, thereby eliminating the margins of
error
associated with positioning each component individually.
The assembling fixture 500 is a large metal mold having an upwardly facing
concave recess providing the aforesaid fixed surfaces. When the fascia 18 and
external components are positioned in the mold, the fixed surfaces support the
fascia
18 and components in place. It is contemplated, however, that any fixture
having
surfaces capable of supporting the fascia 18 and external components in proper
relative orientation may be used as the assembling fixture 500.
While the fascia 18 and external components are positioned in the mold, the
assembly integrating structure (i.e., radiator support structure 48) is
positioned
rearwardly of the components and fascia 18. The components and fascia 18 are
thereafter mounted to the radiator support structure 48 so as to fix the
external
components in the predetermined orientation with respect to the fascia,
thereby
allowing the assembly to be installed on the vehicle without requiring
reorientation of
the components.
FIG. 9 also shows the step of inserting fasteners in the form of bolts 514
through openings 516 formed in the support structure 48. These bolts 514 are
threadingly engaged with openings 518 formed in the fascia 18 and the
components to
fix the same in place. It is to be understood, however, that the same
inserting and
fastening step could be performed by bolts previously secured to the
components and
fascia 18 being received in the same openings 518 as the support structure is
being
moved into position.
With the fascia 18 and external components fixed in place, the assembly 10
can then be removed from the assembling fixture 500 without any relative
movement
occurring between the components and the fascia 18. The cooling module 50 can
then be mounted to the radiator support structure 48 and all other internal
components
(e.g., wiring, etc.) can be secured in place.
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It is to be understood that FIG. 9 is simply a sectional view and other
components will be positioned rearwardly of the fascia 18 before moving the
support
structure 48 into place. Specifically, it is contemplated that the bumper beam
32 will
be positioned rearwardly of the fascia 18 and the fascia support brackets 36,
38 will
be secured to the fascia 18 with the bumper beam 321oosely captured as
described
above.
In another method of the present invention, the fascia 18 itself functions as
the
template. FIG. 11 schematically illustrates the assembling of the module
assembly 10
according to this second method. In this method position controlling portions
of the
fascia 18 defined by position controlling openings guide the external visible
components into their proper orientations and support the components thereat,
thereby
allowing the assembly 10 to be installed on the motor vehicle without
requiring
repositioning of the components. Specifically, the position controlling
opening 1020
formed on the fascia 18 receives position controlling features 1022, 1024 on
the
external components so as to guide the components into proper orientation and
support the components thereat. Preferably, the features 1022, 1024 are
position
controlling guide pins.
In the type of module assembly 10 of FIGS. 1 and 2, the radiator support
structure 48 would then be positioned rearwardly of the fascia 18 and both the
external components and the fascia 18 would then be fastened to the support
structure
48, thereby fixing the components in proper orientation. In the types of
module
assemblies described below with respect to FIGS. 3-6, the radiator support
structure is
pre-mounted to the vehicle itself and thus cannot serve as an anchor point for
the
module assembly. In this type of module assembly -- termed a'non-structural'
module assembly -- the external components may be secured directly to the
fascia 18
in their proper orientations. To effect such direct securement, bolts may be
used (as
shown in FIGS. 3-6) or a snap fit connection may be formed between the
position
controlling features 1022, 1024 and the position controlling openings 1020 to
fix the
components in their proper orientation. Other securement means may optionally
be
used instead. In addition, the cooling module 50 will also be secured directly
to the
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fascia 18, along with various other components such as wiring and the fascia
support
brackets, rather than to a radiator support structure 48.
FIGS. 3 and 4 show a front end module assembly 100 for a framed vehicle
constructed in accordance with a second embodiment of the invention. The
embodiment shown in FIGS. 3 and 4 is similar in all respects to the embodiment
shown in FIGS. 1 and 2 except for the following variations. Similar or
corresponding
parts are designated with the same reference numerals in the figures.
The main difference in the module assembly 100 depicted in FIGS. 3 and 4 is
that its does not include an integral radiator support structure. Rather, the
radiator
support structure 148 in this embodiment forms part of the vehicle or "body-in-
white"
to which the module 100 is mounted. Thus, radiator support structure 148 does
not
form part of the rear group 116, which only comprises cooling module 50.
In this embodiment, the radiator support structure 148 is mounted on the
isolator mounts 67 on the front of the body in white frame structure 163 in
the body
shop as opposed to being bolted onto the front body as part of the module
assembly,
as in the previous embodiment. Thus, the step of mounting the fascia 18 and
the
external components is omitted in the method of assembly. In addition, the
radiator
support structure 148 has been slightly modified, such as being provided with
two
enlarged flanges 84 at its lower edge, thus replacing flange 59 and fender
mounts 54
of the first embodiment. The flanges 84 are mounted on top of and fixed to the
isolator mounting structures 67.
Also in the embodiment of FIGS. 3 and 4, a pair of assembly aid structures or
spacers 46 cooperate with associated brackets 36 and 38. The assembly aid
structures
46 are received within the brackets 36, 38 to facilitate assembly of the
bumper beam
to the front end of a vehicle frame. More particularly, each of the assembly
aids 46
are mounted between the upper and middle legs 39 of an associated one of the
brackets 36 or 38 and are received within the rearwardly facing longitudinal
opening
47 in the rearward end of bumper beam 32 so as to support the bumper beam 32
in
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vertically spaced relation between upper and middle legs 39 of the brackets 36
and 38
within the pre-assembled module 10. The spacers 46 position the bumper beam 32
in
its proper relative orientation with respect to fascia 18, and other parts of
the module
assembly 100, as will be achieved in the final assembly after bumper beam 32
is fixed
to front rail brackets 73. After assembly of the bumper beam 32 to brackets 73
at the
front end of the body-in-white, the assembly aids 46 are removed and then
discarded
or reused. It should be noted, however, that the use of these aids 46 will be
obviated
by the loading fixture described hereinbelow.
The front end module assembly 200 of FIGS. 5 and 6 is similar to the module
illustrated in FIGS. 3 and 4 except that it is adapted for a unibody vehicle.
In this
embodiment, no assembly aids are provided, and the bumper beam 32 is directly
attached to the fascia support brackets 36, 38 because there is no relative
movement
between bumper beam 32 and the body (or any other relative movement between
body/frame components) in a unibody design. Thus, isolator mounts are also
omitted
from the vehicle and the radiator support is rigidly welded to frame 263. In
addition,
the fascia support brackets 36, 38 are modified such that each of the large
central
openings 35 are replaced by two small openings 286 for receiving the bolts
that are
used to fix the nuts 33 of bumper beam 32 to the brackets 36, 38 and also to
the front
rail brackets 73. As with the embodiment of FIGS. 3 and 4, the radiator
support
structure 248 in FIGS. 5 and 6 are not part of the module assembly 200. The
method
of mounting the radiator support structure 248 to the vehicle frame 263 is by
welding
it to the front end of the vehicle frame. In addition, rib members 290 are
welded to
the rear surface of radiator support structure 248. The rib members 290 are in
turn
welded to the frame 263.
After the radiator support structure 248 is welded to the frame 263, the front
end module assembly 200 is secured to the frame 263 and radiator support
structure
248. In particular, the tabs 53 of cooling module 50 are fastened to the lower
panel
275 of radiator support structure 248, and the nuts 33 are secured to the
front rail
brackets 73 mounted to the frame 263. Portions of the fascia 18 are also
mounted to
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portions of the radiator support structure 248, and the latch flange 37 is
fastened to the
upper surface of the upper portion 29 of the fascia 18.
It is to be understood that any of the above embodiments may be used in
conjunction with the subject matter in U.S. Patent No. 6,282,769 to Longo and
Yustick.
Referring now more particularly to FIGS. 7 and 8, a preferred front end
module loading fixture 300 is shown. The fixture 300 facilitates handling of a
front
end module 10, 100, or 200 in accordance with the present invention. The front
end
module loading fixture 300 is comprised of three assemblies: a main supporting
frame, generally depicted at 313, a first lifting fixture in the form of a
pair of upper
lifting fixtures, generally depicted at 315, and a second lifting fixture in
the form of a
pair of lower lifting fixtures, generally depicted at 317. The main support
frame 313
includes a pair of laterally spaced, vertically extending parallel upright
members 368.
As shown in FIG. 8, the parallel members 368 have a lower portion 318
generally
extending straight upwards, a middle portion 320 which angles rearwardly and
upwardly from the lower portion 318, and an upper portion 322 which extends
straight upwards from the upper end of middle portion 320. The uppermost
portion
326 of each parallel member 368 extends upwardly and rearwardly and has a
mounting ring structure 373 having a central opening 374 of compatible size
and
configuration with the attaching members of a conventional hoisting device.
The
parallel upright members 368 are secured and supported in parallel, vertical
disposition by an X-shaped cross-member 370.
A rectangular lower frame structure 372 provides the base support for the
fixture 300 and rests on an assembly support surface or floor. The bottom ends
of the
parallel members 368 are fixed or integrally formed with the front corners of
the
lower frame structure 372.
The upper lifting fixtures 315 each basically comprise a vertically elongated
sleeve-like portion 376 and a lifting structure in the form of a telescoping
and rotating
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lift finger 378. The sleeve-like portions 376 are disposed in surrounding
relation to
the upper portions 322 of the respective upright members 368 and allow the
upper
lifting fixtures 315 to slide along and rotate around the parallel upright
members 368.
Each rotating/telescoping lift finger 378 protrudes horizontally and
rearwardly from a
sleeve portion 376 of an associated upper lifting fixtures 315. Near the
distal end of
each lifting finger 378 is a relatively short knob-like protrusion 380 which
projects
upwards and is configured to be received within the openings 381 in the tabs
51 at the
upper part of the front end module 10, 100, or 200. A disk-like finger stop
382 is
adjustably fixed at a desired vertical position on upper portion 322 of each
parallel
member 368 below the sleeve portion 376 to serve as a lower stop for the
sleeve 376
of the upper lifting fixture 315.
The lower lifting fixture 317 includes a lower lifting structure in the form
of a
vertical post or pick-up finger 384 fixedly secured to or integrally formed
with the
rearward corners of the lower frame structure 372 of the support frame 313.
The
pick-up fingers 384 are of such height and diameter penetrate holes 383 in the
lower
surface of the bumper beam 32. An up/down stop disk 390 is integrally formed
or
fixed at an intermediate portion of each of the pick-up fingers 384 and
provides a
lower support surface for the bumper beam 32 when the module 10, 100, or 200
is
lifted. Fixedly secured in surrounding relation to the base of the pick-up
finger 384,
beneath stop disk 390, is a rubber stop/guide 386 which fits into a hole in
the bottom
surface of the fascia 18. This rubber guide 386 does not support any
substantial
vertical weight, but is used to prevent the lower portions of the front end
module 10
from tipping forward when the module 10 is lifted by the telescoping/rotating
lift
fingers 378.
Use of the front end module loading fixture 300 in accordance with principles
of the invention entails positioning the loading fixture 300 in front of the
front end
module 10, 100, or 200 such that the pick-up fingers 3 84 are somewhat lower
than the
bottom of the fascia 18, the fascia being supported from below by a shipping
skid or
crate. The loading fixture 300 is moved toward the front end module 10, 100,
or 200
until the pick-up fingers 384 are beneath the lift finger holes 383 in bumper
beam 32.
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The fixture 300 is then lifted as needed to insert the pick-up fingers 384
into lift finger
holes 383. The height of lift finger stop members 382 is adjusted such that
the upper
lifting fixtures 315 along the parallel members 368 of the loading fixture
aligns the
rotating/telescoping lifting fingers 378 so that they are approximately at the
same
height or slightly below the forwardly extending portions of the outer tabs 51
with
openings 381. The telescoping lifting fingers 378 are then extended and/or
rotated so
that upward projections 380 are immediately below the openings 381. The
fixture
300 is then hoisted so that projections 380 are received within the openings
381 and
so that the entire module is lifted via lifting fingers 378 and moved to an
installation
position with respect to the vehicle. The bumper beam 32 is independently
lifted by
stops 390 below lift fingers 3 84.
The stops 390 lift the bumper beam 32 to a bumper installation position a
determined distance higher than the nominal design position at which the beam
is
fixed to the frame brackets 73 in order to allow the beam catch 45 to clear
the top of
the front frame brackets 73 upon rearward loading of the module. After the
module
10, 100, 200 is secured to the vehicle (e.g., by fixing radiator support 48 to
fenders 65
or body in the first embodiment; or by fixing the fascia 18 and/or cooling
module 50
to the fenders 65, radiator support 148, or other body components in the
second
embodiment), the fixture 300 is lowered to hook the beam catch 45 on the frame
brackets 73. The bumper beam 32 is now in the design position and temporarily
held
until assembly bolts are used at the next high level assembly line station to
fix the
bumper beam 32 to the brackets 73 at nuts 33.
The loading fixture 300 thus allows the front end module 10, 100, or 200 to be
lifted and supported to facilitate mounting thereof on the forward end of a
vehicle
frame assembly.
It will be thus seen that the object of the present invention has been
achieved
by the foregoing embodiments. The embodiments described herein, however, are
provided to illustrate the functional and structural principles of the present
invention
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701246 CA DIV Patent
and are not intended to be limiting. In contrast, the present invention is
intended to
encompass all modifications and alterations within the scope of the appended
claims.
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