A system and method for designing a customized vehicle repair configuration for effectively measuring and repairing the structure of a damaged vehicle body is disclosed. The system provides a vehicle repair assembly comprising a universal jig assembly, that allows the user to diagnose the damage of the repair structure or vehicle body. The vehicle repair assembly comprises a support frame, the jig assembly, a plate and a height adapter. After diagnosis of the vehicle body, the system is configured to customize the jig assembly respective of the repair structure to generate a customized vehicle repair assembly. The system is further configured to provide edit access to the generated customized vehicle repair assembly to a number of users to tune the generated vehicle repair configuration.

A method for producing an assembly is provided such that manufacturing defects and redundant work steps are preventively avoided.

A vehicle body assembly system each forming a pre-buck section and a main-buck section set along a transport path of the floor assembly according to an exemplary embodiment of the present disclosure includes a pre-buck unit configured in the pre-buck section to regulate the seal side and the front and rear sides of side assemblies that are different for each vehicle type, and to assemble the side assembly and the floor assembly, and a main-buck unit configured in the main-buck section to regulates the roof portion and the quarter portion of the side assembly assembled to the floor assembly in the pre-buck section, assemble the roof portion, cowl, roof rail and package tray and assemble the quarter portion and the floor assembly.

A door attachment method assembles a door with a high degree of accuracy. Embodiments include a primary fastening step of bolting hinges to attachment surfaces of a vehicle body; a door panel position measurement step of measuring a relative position of a door panel in an opening when a door is brought into a cantilevered state and the hinges are fastened; a loosening step of loosening the fastening; a door position correction step of moving the door within the attachment surfaces based on a measurement result in the door panel position measurement step; and a secondary fastening step of re-fastening the hinges to the attachment surfaces. Throughout the primary fastening step, the door panel position measurement step, the loosening step, the door position correction step, and the secondary fastening step, a state where clamps respectively grip the hinges to cause the hinges to abut the attachment surfaces is maintained.

A vehicle body assembly system each forming a pre-buck section and a main-buck section set along a transport path of the floor assembly according to an exemplary embodiment of the present disclosure includes a pre-buck unit configured in the pre-buck section to regulate the seal side and the front and rear sides of side assemblies that are different for each vehicle type, and to assemble the side assembly and the floor assembly, and a main-buck unit configured in the main-buck section to regulates the roof portion and the quarter portion of the side assembly assembled to the floor assembly in the pre-buck section, assemble the roof portion, cowl, roof rail and package tray and assemble the quarter portion and the floor assembly.

A system for controlling manufacturing of a vehicle door can set a position of the door by predicting a deflection thereof. The system includes a control unit detecting weight data of the door by vehicle model and position range data, generating a door deflection amount and a body deflection amount based on the weight data and the position range data, detecting a gap prediction value and a step difference prediction value according to the door deflection amount and the body deflection amount, and generating a result list including positioning data of the hinge unit if the gap prediction value and the step difference prediction value exist within a quality reference range, and a prediction unit configured to predict the gap prediction value and the step difference prediction value at which the body and the door are spaced apart based on the door deflection amount and the body deflection amount.

A method of supporting vehicle panel assemblies of different lengths for a measuring operation using a coordinate measurement machine is provided. The method includes supporting a first vehicle panel assembly having a first length on a holding gage assembly comprising horizontally aligned datum locations of a first set of datum members that support the first vehicle panel assembly thereon. A second vehicle panel assembly having a second length that is greater than the first length is supported on the datum locations of the first set of datum members. The second vehicle panel assembly extends longitudinally beyond the datum locations of the first set of datum members to at least one datum location of a second set of datum members.

A system and method for determining alignment of a first part relative to a second part includes an alignment gauge body including a first portion for resting against the first part and a second portion for positioning juxtaposed to the second part and a measuring device fixedly coupled to the alignment gauge body. The measuring device generates a distance signal corresponding to a distance between a first face of the first part and the second face of the second part. A controller coupled to the gauge device and a memory. The controller is programmed to store a vehicle identification number (VIN) in the memory and compare the distance. The controller associates the VIN and the distance in the memory. The controller compares the distance to a threshold and setting a flag in response to comparing. A display coupled to the controller displays an indicator corresponding to the flag.

A method for testing the dimensional accuracy of transportable positioning devices for the production of a motor vehicle. The method includes providing locaters on positioning devices so that each body component of the motor vehicle is accurately geometrically positioned on a respective one of the positioning devices. The method also includes moving, in a motor vehicle production cycle, the positioning devices with the respective body component positioned thereon to different workstations. The method further includes measuring, by a control unit during the motor vehicle production cycle in the workstations and/or in an inline measuring station for an acquisition of measured values in the motor vehicle production cycle, predefined measuring points on each body component positioned on the positioning device. The method additionally includes evaluating, by the control unit, the predefined measuring points to determine a dimensional accuracy of the transportable positioning device.

A method of assembling a manufactured item without a guide rail and an assembly system are provided. The method includes disposing a base item on an unmanned independent vehicle system, moving the unmanned independent vehicle system to an assembly station, and attaching an additional item to the base item. The assembly system includes a number of unmanned independent vehicle systems, each unmanned independent vehicle system having at least one wheel. Each unmanned independent vehicle system is configured to be loaded with a base item. A number of assembly stations are provided, each being configured to complete at least one assembly operation. Each unmanned independent vehicle system is configured to independently move to multiple of the assembly stations to have a different assembly operation performed at each assembly station, resulting in additional items being attached to each base item to form each manufactured item.