Vehicle frame turnover system and method

A method for turning over an elongated vehicle frame defining openings and having a longitudinal center axis, the vehicle frame being one of a plurality of different vehicle frame types, the method comprising:

• providing a first multi-axis robot having a first end effector and a second multi-axis robot having a second end effector, wherein each of the first and second end effectors has a pair of oppositely-positioned locator pins, at least one of which is selectively moveable toward the other, and wherein each of the locator pins has a plurality of tiers, the tiers each having a different relative diameter, with each of the tiers having a tapered surface, and a first of the tiers having a smallest of the relative diameters and a conical end;
• determining whether the vehicle frame is a first or a second of the different vehicle frame types;
• aligning, via a controller in communication with the multi-axis robots, the locator pins of the first and second end effectors with the openings defined by the vehicle frame;
• inserting the aligned locator pins a first or a second distance into the openings toward the center axis from outside of the vehicle frame responsive to a determination that the vehicle frame is the first or the second vehicle frame type, respectively, the inserting including inserting at least one of the first and second tiers of the aligned locator pins into the opening;
• lifting the vehicle frame from a first conveyor using the first and second end effectors, wherein weight of the vehicle frame is supported by the locator pins during the lift;
• rotating the vehicle frame about the longitudinal center axis via the first and second multi-axis robots in response to motor control commands from the controller;
• and
• lowering the vehicle frame onto a second conveyor via the first and second multi-axis robots.

A system for turning over a vehicle frame having support rails defining a set of openings and having a longitudinal center axis, the vehicle frame being one of a plurality of different vehicle frame types, the system comprising:

• a first six-axis robot having a first end effector;
• a second six-axis robot having a second end effector, the first and second end effectors each having a pair of oppositely-positioned locator pins, the locator pins each defining a plurality of tiers of different relative diameters with each of the tiers having a tapered surface, and a first of the tiers having a smallest of the relative diameters and forming a conical end, at least one of the pins being selectively moveable toward the other;
• and
• a controller having a processor and tangible, non-transitory memory on which is recorded instructions for positioning the vehicle frame using the first and second end effectors, wherein the controller is in communication with first and second six-axis robots, and is configured to execute the instructions from the memory via the processor to determine whether the vehicle frame is a first or a second of the different vehicle frame types and to cause the first and second six-axis robots to:
• align the locator pins of the first and second end effectors with the openings defined by the longitudinal support rails of the vehicle frame;
• responsive to a determination that the vehicle frame is the first vehicle frame type, insert a fixed one of the aligned locator pins a first distance into a first of the openings toward the center axis from outside of the vehicle frame via movement of the first six-axis robot;
• responsive to a determination that the vehicle frame is the second vehicle frame type, insert the fixed one of the aligned locator pins a second distance into the first of the openings toward the center axis from outside of the vehicle frame via movement of the first six-axis robot;
• align the vehicle frame with respect to the first carrier using the first end effector prior to inserting the locator pins of the second end effector;
• insert a moveable one of the aligned locator pins into a second set of the openings toward the center axis from outside of the vehicle frame via release of pressure from a pneumatic or a hydraulic cylinder;
• lift the vehicle frame in an inverted position from a first conveyor using the first and second end effectors, wherein weight of the vehicle frame is supported by the locator pins during the lift;
• rotate the vehicle frame about the longitudinal center axis;
• and
• lower the vehicle frame in an upright position onto a second conveyor.