# US 7,406,766 B2 · Apparatus and method for assembling a part for an automotive vehicle > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,406,766 B2 - Document ID: US7406766B2 - Status: Granted - Kind: B2 - Application number: 10/968,505 - Filed: 2004-10-19 - Published: 2006-04-20 - Granted: 2008-08-05 - Earliest claimed: 2004-10-19 - Assignees: BBI Enterprises, L.P. - Inventors: Michael Levesque; Steven G Brown; Guy W Boitos; Karem Akawi - Web page: https://patentgrep.com/patent/US7406766B2 ## CPC - B62D 25/2054: {Load carrying floors for commercial vehicles} - B21D 39/021: {for panels, e.g. vehicle doors} - Y10T 29/49622: Vehicular structural member making - Y10T 29/49895: Associating parts by use of aligning means [e.g., use of a drift pin or a "fixture"] - Y10T 29/49915: Overedge assembling of seated part - Y10T 29/49924: of parallel side-by-side elongated members - Y10T 29/49945: by driven force fit - Y10T 29/49998: Work holding - Y10T 29/53039: with control means energized in response to activator stimulated by condition sensor - Y10T 29/53061: Responsive to work or work-related machine element - Y10T 29/53065: with means to fasten by deformation - Y10T 29/53709: Overedge assembling means - Y10T 29/53961: with work-holder for assembly - Y10T 29/53996: by deforming - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) - B21D: WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL (working or processing of wire B21F) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract An apparatus (10) of the present invention is designed for assembling a load floor (12) having a peripheral slot (22) and an overlaying layer (24, 28). The apparatus (10) tucks the overhang of the overlaying layer (24, 28) into the peripheral slot (22). At least one holding device (52) holds the load floor (12). At least one tucking tool (54) tucks the overhang of the overlaying layer (24, 28) into the peripheral slot (22) to fold the overhang over the peripheral slot (22) and thereafter tucking the overhang into the peripheral slot (22). The invention includes a method of sequentially folding and thereafter tucking the overhang of the overlaying layers (24, 28) into the peripheral slot (22). ## Claims ### Claim 1 An apparatus for assembling a panel having opposite surfaces and sides interconnected by corners and having a peripheral slot defined therein and at least one overlaying layer extending over one of the opposite surfaces and for tucking the overhang of the overlaying layer into the peripheral slot, said apparatus comprising; an actuation system having a clamping assembly for holding the panel, and at least one tucking tool of said actuation system having a tucking blade for tucking the overhang into the peripheral slot and effecting relative movement between the panel and said at least one tucking tool in a direction transverse to the opposite surfaces of the panel with said at least one tucking tool disposed in overlapping relationship with the overhang to fold the overhang over the peripheral slot and for thereafter effecting relative movement in a direction parallel to the opposite surfaces of the panel to move said at least one tucking tool into the peripheral slot to tuck the overhang into the peripheral slot. ### Claim 2 (depends on 1) An apparatus as set forth in claim 1 wherein said clamping assembly includes panel actuators for effecting said relative movement between the panel and said at least one tucking tool in said transverse direction. ### Claim 3 (depends on 2) An apparatus as set forth in claim 2 wherein said at least one tucking tool is further defined by a plurality of said tucking tools spaced one from the other for surrounding the panel about the peripheral slot. ### Claim 4 (depends on 3) An apparatus as set forth in claim 3 wherein each of said plurality of tucking tools includes a tucking actuator for moving said plurality of tucking tools parallel to the panel. ### Claim 5 (depends on 4) An apparatus as set forth in claim 4 including a controller for sequencing said panel actuators and said tucking actuators relative to one another and relative to the panel. ### Claim 6 (depends on 5) An apparatus as set forth in claim 5 wherein said plurality of tucking tools is further defined by a plurality of side tucking tools for tucking the overhang of the overlaying layer into the peripheral slot about the sides of the panel and a plurality of corner tucking tools for tucking the overhang of the overlaying layer into the peripheral slot about the corners of the panel. ### Claim 7 (depends on 6) An apparatus as set forth in claim 6 wherein said panel actuators of said clamping assembly are further defined by a plurality of pushing devices for applying a force to one of the opposite surfaces thereby pushing the panel in said transverse direction. ### Claim 8 (depends on 7) An apparatus as set forth in claim 7 wherein said panel actuators of said clamping assembly are further defined by at least one ejector for supporting the other of the opposite surfaces for moving the panel clamped therebetween in unison with said pushing devices as sequenced by said controller in different tucking modes of said apparatus. ### Claim 9 (depends on 8) An apparatus as set forth in claim 8 wherein each said panel actuator is a pneumatic actuator. ### Claim 10 (depends on 5) An apparatus as set forth in claim 5 wherein each tucking actuator is a pneumatic actuator having a pneumatically operated cylinder and a pair of spaced shafts horizontally movable relative to the panel. ### Claim 11 (depends on 10) An apparatus as set forth in claim 10 wherein each tucking tool includes a blade support connected to said spaced shafts. ### Claim 12 (depends on 10) An apparatus as set forth in claim 10 wherein said tucking blade is supported by said blade support for tucking the overhang of the overlaying layer into the peripheral slot. ### Claim 13 (depends on 12) An apparatus as set forth in claim 12 including a source of a fluid supply fluidly communicated with said tucking actuators, said panel actuators for supplying fluid and facilitating pneumatical motion of said tucking actuators and said panel actuators. ### Claim 14 (depends on 13) An apparatus as set forth in claim 13 wherein said tucking blade presents a planar configuration. ### Claim 15 (depends on 13) An apparatus as set forth in claim 13 wherein said tucking blade presents a concave configuration. ### Claim 16 (depends on 13) An apparatus as set forth in claim 13 wherein said tucking blade presents a convex configuration. ### Claim 17 (depends on 13) An apparatus as set forth in claim 13 including a frame presenting a plurality of vertical posts interconnected by upper and lower horizontal beams. ### Claim 18 (depends on 17) An apparatus as set forth in claim 17 including a support panel connected to said frame for supporting the panel. ### Claim 19 (depends on 18) An apparatus as set forth in claim 18 wherein said support panel presents an opening defined therein with said opening being smaller than the perimeter of the panel with said pushing devices and said at least one ejector extending through said opening with respect to different tucking modes of said apparatus. ### Claim 20 (depends on 19) An apparatus as set forth in claim 19 including side and corner retaining elements adjustably connected to said support panel and suffounding said opening for holding the panel relative said support panel with said side and corner retaining elements slidably movable relative said opening. ### Claim 21 (depends on 20) An apparatus as set forth in claim 20 wherein said pushing devices are operably connected to said upper horizontal beams and oriented around the perimeter of the panel. ### Claim 22 (depends on 21) An apparatus as set forth in claim 21 including a sensor connected to each of said panel actuators and said tucking actuators for controlling tucking modes of said panel actuator and tucking actuators. ### Claim 23 (depends on 22) An apparatus as set forth in claim 22 including at least one mirror connected to said frame for reflecting images of the panel as said tucking tools move relative to the panel. ### Claim 24 (depends on 23) An apparatus as set forth in claim 23 including a pair of sleeves connected to said lower horizontal beams for receiving forks of a fork-lift truck. ### Claim 25 (depends on 24) An apparatus as set forth in claim 24 including a device operably connected to said lower horizontal beam with said device pivotably and radially rotatable relative the panel for forming a cavity in the panel and inserting a handle into the cavity of the panel. ### Claim 26 A method for assembling a panel having opposite surfaces and sides interconnected by corners and having a peripheral slot defined therein and at least one overlaying layer extending over one of the opposite surfaces and for tucking the overhang of the overlaying layer into the peripheral slot, said method comprising the steps of; providing a clamping assembly to clamp the panel on the opposite surfaces, providing at least one tucking tool to tuck the overhang into the peripheral slot, and sequentially moving the clamping assembly and the at least one tucking tool relative to one another and in a direction transverse to the opposite surfaces of the panel to dispose the overhang in overlapping relationship with the at least one tucking tool and to force the overhang into the peripheral slot thereby retaining the overhang of each layer in the peripheral slot in an adhesive free manner. ### Claim 27 (depends on 26) A method as set forth in claim 26 including the step of folding the overhang over the peripheral slot. ### Claim 28 (depends on 27) A method as set forth in claim 27 wherein the step of folding the overhang over the peripheral slot is further defined by the step of moving the at least one tucking tool into the peripheral slot and to tuck the overhang into the peripheral slot. ### Claim 29 (depends on 28) A method as set forth in claim 28 wherein the step of providing at least one tucking tool is further defined by providing a plurality of the tucking tools spaced one from the other to suffound the panel about the peripheral slot. ### Claim 30 (depends on 26) A method as set forth in claim 26 wherein the step of providing the clamping assembly is further defined by providing a plurality of pushing devices to apply a force to one of the opposite surfaces to push the panel in the transverse direction. ### Claim 31 (depends on 30) A method as set forth in claim 30 wherein the step of providing the clamping assembly is further defined by providing at least one ejector to support the other of the opposite surfaces and to move the panel clamped between the pushing devices and the ejector in unison in different tucking modes of said method. ### Claim 32 (depends on 31) A method as set forth in claim 31 including the step of connecting a sensor to each of the pushing devices and each of the tucking tools, and to the ejector to control tucking modes of the pushing devices, the tucking tools, and the ejector. ### Claim 33 (depends on 32) A method as set forth in claim 32 including the step of connecting a controller to the pushing devices, the tucking tools, and the ejector to sequence movement of the pushing devices, the tucking tools, and the ejector relative to one another and relative to the panel. ### Claim 34 (depends on 33) A method as set forth in claim 33 including the step of connecting a source of a fluid supply to the pushing devices, the tucking tools, and the ejector to supply fluid and facilitating pneumatical motion of the tucking tools, the pushing devices, and the ejector. ### Claim 35 An apparatus for assembling a panel having opposite surfaces and sides interconnected by corners and having a peripheral slot defined therein and at least one overlaying layer extending over one of the opposite surfaces and for tucking the overhang of the overlaying layer into the peripheral slot, said apparatus comprising; an actuation system having a clamping assembly for holding the panel, and at least one tucking tool of said actuation system for tucking the overhang into the peripheral slot and effecting relative movement between the panel and said at least one tucking tool in a direction transverse to the opposite surfaces of the panel with said at least one tucking tool disposed in overlapping relationship with the overhang to fold the overhang over the peripheral slot and for thereafter effecting relative movement in a direction parallel to the opposite surfaces of the panel to move said at least one tucking tool into the peripheral slot to tuck the overhang into the peripheral slot; said clamping assembly including panel actuators for effecting said relative movement between the panel and said at least one tucking tool in said transverse direction; said at least one tucking tool being further defined by a plurality of said tucking tools spaced one from the other for suffounding the panel about the peripheral slot, wherein each of said plurality of tucking tools includes a tucking actuator for moving said plurality of tucking tools parallel to the panel; a controller for sequencing said panel actuators and said tucking actuators relative to one another and relative to the panel; said plurality of tucking tools being further defined by a plurality of side tucking tools for tucking the overhang of the overlaying layer into the peripheral slot about the sides of the panel and a plurality of corner tucking tools for tucking the overhang of the overlaying layer into the peripheral slot about the corners of the panel; said panel actuators of said clamping assembly are further defined by a plurality of pushing devices for applying a force to one of the opposite surfaces thereby pushing the panel in said transverse direction and at least one ejector for supporting the other of the opposite surfaces for moving the panel clamped therebetween in unison with said pushing devices as sequenced by said controller in different tucking modes of said apparatus with each said panel actuator being a pneumatic actuator; and each tucking actuator is a pneumatic actuator having a pneumatically operated cylinder and a pair of spaced shafts horizontally movable relative to the panel with each tucking tool including a blade support connected to said spaced shafts. ### Claim 36 (depends on 35) An apparatus as set forth in claim 35 wherein each tucking tool includes a tucking blade is supported by said blade support for tucking the overhang of the overlaying layer into the peripheral slot. ### Claim 37 (depends on 36) An apparatus as set forth in claim 36 including a source of a fluid supply fluidly communicated with said tucking actuators, said panel actuators for supplying fluid and facilitating pneumatical motion of said tucking actuators and said panel actuators. ### Claim 38 (depends on 37) An apparatus as set forth in claim 37 wherein said tucking blade presents a planar configuration. ### Claim 39 (depends on 38) An apparatus as set forth in claim 38 wherein said tucking blade presents a concave configuration. ### Claim 40 (depends on 38) An apparatus as set forth in claim 38 wherein said tucking blade presents a convex configuration. ### Claim 41 (depends on 40) An apparatus as set forth in claim 40 including a frame presenting a plurality of vertical posts interconnected by upper and lower horizontal beams. ### Claim 42 (depends on 38) An apparatus as set forth in claim 38 including a support panel connected to said frame for supporting the panel. ### Claim 43 (depends on 42) An apparatus as set forth in claim 42 wherein said support panel presents an opening defined therein with said opening being smaller than the perimeter of the panel with said pushing devices and said at least one ejector extending through said opening with respect to different tucking modes of said apparatus. ### Claim 44 (depends on 43) An apparatus as set forth in claim 43 including side and corner retaining elements adjustably connected to said support panel and surrounding said opening for holding the panel relative said support panel with said side and corner retaining elements slidably movable relative said opening. ### Claim 45 (depends on 44) An apparatus as set forth in claim 44 wherein said pushing devices are operably connected to said upper horizontal beams and oriented around the perimeter of the panel. ### Claim 46 (depends on 45) An apparatus as set forth in claim 45 including a sensor connected to each of said panel actuators and said tucking actuators for controlling tucking modes of said panel actuators and tucking actuators. ### Claim 47 (depends on 46) An apparatus as set forth in claim 46 including at least one mirror connected to said frame for reflecting images of the panel as said tucking tools move relative to the panel. ### Claim 48 (depends on 47) An apparatus as set forth in claim 47 including a pair of sleeves connected to said lower horizontal beams for receiving a forks of a fork-lift truck. ### Claim 49 (depends on 48) An apparatus as set forth in claim 48 including a device operably connected to said lower horizontal beam with said device pivotably and radially rotatable relative the panel for forming a cavity in the panel and inserting a handle into the cavity of the panel.