| A steel ball bearing would have a smooth, slick ride along the even gap that separates the front bumper and fascia on the 1997 Dodge Ram truck. That close, consistent gap is created with a special alignment fixture designed and built by Peak Industries, Inc., Dearborn, Mich. The fixture is mounted on and manipulated by an Ergo arm, Peak's versatile lifting and handling system.
The pneumatically operated fixture is a modular device consisting of a welded frame, cross-arms, locating blocks, slides, and clamps. It is used to move the front bumper into its designed position next to the fascia as the truck chassis moves down the line. The fixture compensates for manufacturing tolerances that otherwise might result in an uneven and noticeable gap separating the bumper and fascia.
The truck chassis arrives at the work station with the bumper hanging loosely in its approximate final position. One operator, using the Ergo arm, moves the fixture to place locating pads on the sides of the radiator, establishing the fixture's correct lateral position. Other moves of the fixture establish its longitudinal and vertical positions.
At this point, the fixture frame is locked into final position and clamped to the chassis. The Ergo arm operator then proceeds to actuate two slides and two forks with rollers to move the bumper into place on the chassis. Finally, two operators, using nut runners, secure the bumper to the chassis with four bolts.
As in most other applications to date, the Peak Ergo arm hangs from an overhead bridge (carriage) that rides on rails. The cylinder-actuated arm has an integral handle and control buttons. A balance system that produces zero gravity enables the operator to raise and lower the arm and its load with the touch of a finger and with essentially no effort.
Three buttons are used to control the arm. A High Balance button puts the arm in a transport mode. A Balance Fixture button produces the zero gravity condition. And, a Low Balance button permits the arm to be locked in position when a fixed holding mode is required. Peak engineers designed the Dodge truck fixture using computer product data rather than actual hardware. This time-saving approach has proved effective in many of the special machines and systems developed recently by the company.
Peak Industries has been a supplier of custom automation and assembly components and special machines and systems for the automotive and other manufacturing industries since 1966.
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