Straightener and Method of Use for Vehicle Inspection

BACKGROUND OF THE INVENTION

[0001] When a vehicle accident occurs, impact forces may cause damage beyond simple surface dents and dings. An auto body’s structural frame can twist, bend, or otherwise distort. This is a design component that allows crash energy to be displaced, while protecting vehicle cargo such as human life. If a vehicle was more rigidly constructed, included cross bracings, or otherwise was designed not to distort; more impact energy from collisions would be transferred to vehicle occupants, increasing the risk and severity of human injury and possible loss of life.

[0002] Vehicle body panels, windows, and other surface components are relatively easy to replace. But a vehicle’s structural frame is not replaceable. Any structural damage to a frame must be accurately identified and properly repaired before any further restoration of the vehicle can occur. Until a vehicle frame is restored to true alignment, a vehicle’s body components may not look, fit, or operate correctly.

[0003] Vehicle frame misalignment may appear as simple cosmetic issues, miscellaneous squeaks while driving, sticking doors/compartment covers, and/or stress fractures in windows or interior plastic panels. Frame misalignment may cause severe performance issues; such as improper tracking, excessive tire wear, and unsafe handling during turning or at higher speeds.

[0004] Using auto body frame machines and other supplemental equipment, an experienced auto repair professional can return a damaged frame to factory specifications. Auto body frame machines use manual operation of hydraulics, providing torque and leverage in a controlled manner, to pull a damaged frame back into alignment. Auto body frame machines, are also referred to as frame straightening machines or simply as frame straighteners.

[0005] Frame straighteners comprise a platform, on which to suspend a vehicle securely in an elevated position such that forces can be applied in a controlled manner. Suspending the vehicle in an elevated position allows forces to be applied without friction, or counter forces of the usual surface contact at the tire locations, or force dampening to occur via springs, shocks, and other vehicle components.

[0006] A completely suspend vehicle’s tires can be removed to provide convenient access to damaged areas, and to allow more complete measurements without variable interference of vehicle loading on movable suspension points which tires comprise. A suspended vehicle also has the added convenience of being adjustable to a comfortable working height, reducing worker fatigue and/or avoiding worker injury.

[0007] Multiple upright post or towers are positioned around the platform perimeter to access different areas of a vehicle frame for applying shaping forces to the frame at any desired angle or strength. More elaborate frame straighteners further comprise on-board measuring equipment, such as line-of-sight lasers, sonic senders, and other unique 3-dimentional measuring systems, to diagnose alignment, assisting in estimating repair procedures required; and confirm accurate completion of frame re-alignment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Fig 1 is an illustration of an embodiment of a floor mount auto body frame machine. [0009] Fig 2 Illustrates an auto body frame machine being utilized to straighten front-end damage on a mounted vehicle.

[0010] Fig 3A shows a close-up of a cleat rail along the outer sides of an auto body frame machine and the cleat channels found thereon.

[0011] Fig 3B illustrates a body stand mounted to a cleat rail and mated with a pinch weld clamp for attachment to a vehicle undercarriage to support the vehicle on the frame machine.

[0012] Fig 4A shows a cross section of a cleat fastener utilized to secure accessories to a frame machine’s cleat rails.

[0013] Fig 4B is a perspective view of a cleat fastener’s components.

[0014] Fig 5 is a perspective illustration of an above ground wheel ramp attached to a frame machine’s cleat rails to support a vehicle during initial lifting and mounting of the accessory body brackets.

[0015] Fig 6 shows an in-ground wheel tray assembly in accordance with an exemplary embodiment of the invention.

[0016] Fig 7 shows an illustration of an in-ground wheel tray assembly engaged with a cleat rail of an in-ground mounted frame machine positioned to provide maximum ground clearance, in an exemplary embodiment of the innovation. [0017] Figs 8A - 8C show a series of cross section views illustrating an in-ground wheel tray assembly and the various engagements with the cleat rail of an in-ground frame machine as the frame machine lifts a vehicle in an exemplary embodiment of the innovation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] Frame damage is quite common, occurring in approximately fifty percent of all auto accidents. This is because the frame is the foundation of the vehicle and changes in a frame can affect alignment of body parts; and cause interference between moveable parts such as hoods, doors, and windows. Misalignment may be as minor as joints having variable gaps which are unsightly, to extremes that prevent proper latching and security of a vehicle or affect passenger safety.

[0019] Auto body frame straightening machines (a.k.a. frame straighteners or frame machines) are used to assess damage and re-align the vehicle’s underlying frame using hydraulics power, torque, and leveraged force. Frame straighteners may have various configurations but are primarily comprised of structural hydraulic lifts and support which come in various

configurations such as movable, floor mounted, or in-ground mounted configurations.

[0020] Frame machines provide the hydraulics and torque required to straighten auto body frames. Frame machines have accessories to supporting vehicles, or for providing leverage during straightening operations. These accessories typically mount to the outer rail of the frame machine using cleat fasteners to affix to cleat mounting rails of the frame machines. [0021] Frame machines are large and costly pieces of equipment. Use of a frame machine can be maximized by limiting the amount of time it takes to mount a vehicle to access and/or repair damage. Frame machines may also be mounted via an in-ground configuration where the frame machine lowers to below ground level to store in a pit in the floor of a vehicle service bay. This allows the vehicle service bay containing the frame machine to be utilized to perform other vehicle repair and maintenance task by stowing the frame machine in the in-floor pit below ground level when not required for repair operations.

[0022] To utilize a frame machine, a damaged vehicle is driven or winched onto wheel ramps which hang along the side rail (the cleat rail). In another embodiment, utilizing a moveable frame machine, a damaged vehicle is raised a significant height to allow the frame straightener to be positioned underneath. The vehicle is then mated to the frame straightener and both are elevated to a comfortable working height. Once the vehicle is supported, the wheels and the wheel ramps are removed to provide unrestricted access to measuring equipment which access misalignment for repair purposes.

[0023] To utilize a frame floor mounted machine, a damaged vehicle is driven or winched onto wheel ramps which hang along the side rail (the cleat rail). The vehicle is then lifted to a comfortable working height and supported on accessory body brackets mated with pinch weld clamps or other body mounting clamps. Once the vehicle is supported, the tires and the wheel ramps are removed to provide unrestricted access to measuring equipment which access misalignment for repair purposes. [0024] When a frame machine is mounted in an in-floor configuration, the pit holding the machine has walls directly next to the frame to minimize trip hazards. This prevents wheel ramps from being left on the frame machine as it is lowered into a storage pit.

[0025] To utilize an in-ground frame machine, the frame machine can be lifted above ground level, and wheel ramps installed on the cleat rails, then the frame machine is used in the same manner as an above ground mounted frame machine. Another option is to park the vehicle over the in-floor frame machine, then raise the vehicle to support the tires on wheel stands.

[0026] The frame machine is then lifted to mate with the vehicle and support it on accessory body brackets mated with pinch weld clamps or other body mounting clamps. Once the vehicle is supported, it is raised to a comfortable working height and the wheel stands and tires are removed to provide unrestricted access to measuring equipment which access misalignment for repair purposes.

[0027] Another option is to utilize low-profile wheel trays in place of wheel ramps to allow easier loading of a vehicle and eliminate the need for decking or mounting slopes used to drive a vehicle onto an above ground mounted frame machine. Wheel trays are mounted to the top of a frame machine’s cleat rail and project outward from the frame machine’s frame to extend under and past the edge of a vehicle’s tires span, or track. In one embodiment, the outer most edge of the wheel tray has a raised stop or bumper preventing a vehicle from moving sideways off the wheel tray. [0028] To utilize an in-ground frame machine with in-ground wheel trays, the vehicle is driven over the in-ground pit, so as to straddle the frame machine. The wheel trays are angled upward on the outside edge to an approximate 90-degree angle so the wheel tray’s mounting support’s cleat locking ledge can be drop into the cleat channel and engaged with the inner cleat locking groove of the cleat rail. The outside edge of the wheel tray is then lowered to engage the mounting base’s cleat removal curve against the outer wall of the cleat rail’s cleat channel and further force the mounting support’s cleat locking ledge into the cleat channel’s inner cleat locking groove.

[0029] Once all four in-ground wheel tray assemblies are in place, the vehicle is driven up the wheel tray’s ramps to park on the wheel tray’s anti-roll curve. The anti-roll curve prevents the vehicle from moving forward or backward by keeping the vehicle centered on the wheel tray. As the frame machine lifts, the mounting support lifts atop the cleat rail and the wheel tray remains stable, with the slide pin dropping relative to the mounting support’s slide until the wheel tray’s locking ledge engages in the cleat rail’s outside locking groove, at which point the wheel tray, and the vehicle rises into the air to a comfortable working height.

[0030] The vehicle can then be supported on accessory body brackets mated with pinch weld clamps or other body mounting clamps, and the tires and wheel trays removed. However due to the minimal nature, cleat fasteners can be added to the mounting supports, and the in-ground wheel tray assemblies remain, unless work access requires the vehicle’s wheel removal. This provides a level of security while allowing the tires and wheel trays may remain in place on the vehicle. [0031] The in-ground wheel tray assembly requires minimal ground clearance, to install and quickly secures, in a safe locking manner, to the cleat rail of an in-ground mount frame machine positioned in a lowered configuration to provide maximum ground clearance to any vehicle. Once a vehicle is lifted to a comfortable working height, additional safety precautions can be carried out to further lock the wheel tray assemblies prior to working under the vehicle. The wheel trays are significantly less intrusive into working spaces than traditional wheel ramps, but they also can be replaced by body brackets and under carriage mounting to allow tire, wheel, and wheel tray removal in the same manner as traditional wheel ramps.

[0032] To load a low ground clearance vehicle onto an in-ground frame machine utilizing an exemplary embodiment of the innovations described herein, one would ensure the wheel trays were disengaged from the frame machine and placed out of the way. The vehicle would be positioned such that the wheel’s tracks straddled the frame machine’s platform with the cleat rails running inside of the tires under the vehicle, with the vehicle slightly back of being centered along the length of the platform.

[0033] Each wheel tray assembly is positioned the same distance relative to each respective wheel. The outer edge of wheel tray is held elevated to the mounting support at an approximate angle of 30 degrees, then the inner edge of the mounting support is slid into the cleat channel so the cleat locking engages the inner cleat locking groove. The wheel tray is then lowered to the ground and the mounting support’s cleat removal curve seats against the outer wall of the cleat channel. [0034] Once all wheel trays are in place, the vehicle is pulled forward over the wheel tray’s leading ramp, and rest with the four tires upon the wheel trays in the anti-roll curve. Once positioned, the frame machine’s platform is elevated.

[0035] The weight of the vehicle on the wheel trays causes the mounting base’s mounting slide to rise relative to the wheel tray’s slide pin, until the wheel tray’s locking ledge along the lower side of the tray’s base engages the cleat rail’s outside locking groove, securing the wheel tray assembly to the cleat rail before the vehicle is lifted off the ground. This security will remain engaged until the elevated vehicle’s weight is shifted to under carriage brackets.

[0036] Once the weight is released from the wheels, the wheel tray may be lifted straight up along the mounting slide, to disengage the outside locking groove. Then the entire wheel tray assembly can be slid along the cleat rail to either side of the wheel, and finally lifted by the outer edge of the tray to disengage the mounting base from the cleat and completely removed. Or as an alternative, cleat fasteners can be secured to either side of the in-ground wheel tray assembly’s mounting base and secured in place.

[0037] Fig 1 is an illustration of an embodiment of a floor mount auto body frame machine. The auto body frame machine also known as a frame straightening machine or simply a frame machine (2000) comprises a main structural support or platform (2100, not indicated) having cleat rails (2110) running along either side for supporting tools and accessories. In the illustration the cleat rails (2110) have a plurality of wheel ramps (2700) attached to the cleat rails (2110) allowing a vehicle to be driven onto the frame machine (2000). [0038] Once a vehicle is positioned on the frame machine (2000), one or more towers (2600) can be attached to the platform (2100) in the manner illustrated, allowing hydraulic pullers (2660) to exert force on chains (2650, not shown) attached to various chain points (2640) and affixed to the vehicle to return a damaged vehicle to factory specific alignment.

[0039] Fig 2 Illustrates an auto body frame machine being utilized to straighten front-end damage on a mounted vehicle. Note that the platform of the frame machine is optionally raised to a comfortable working height rather than remaining near the ground. A vehicle (1000) is held by pinch weld clamps (2320) mounted to body stands (2300) secured to the cleat rail (2110) of the frame machine’s platform (2100, not indicated).

[0040] The tires (1130) have been removed exposing the rotors (1135) and providing unimpeded access to the measuring rail (2135) and measuring tools. The structural frame (1110) can be straighten to support body panels (1120) by pulling with a hydraulic puller (2660) transferring controlled forces through a chain (2650) mounted to one of various mount points (2640) on the variably positional tower (2600).

[0041] Fig 3A shows a close-up of a cleat rail along the outer sides of an auto body frame machine and the cleat channels found thereon. A cleat rail (2110) has a cleat channel (2113) along the top edge with an inner cleat locking groove (2115) and an outer cleat locking groove (2117) on each side. There is an outside locking groove (2120) along the edge of the cleat rail (2110) external to the frame machine (2000). [0042] Fig 3B illustrates a body stand mounted to a cleat rail and mated with a pinch weld clamp for attachment to a vehicle undercarriage to support the vehicle on the frame machine. Note an adjustable body bracket can adjust the height of the body to initially mate with the undercarriage, and further to release the weight from the tires for wheel removal. The illustration shows a pinch weld clamp (2320) mounted to the top of a body bracket accessory (2300) secured to the cleat rail (2110) by cleat fasteners (2400).

[0043] Fig 4A shows a cross section of a cleat fastener utilized to secure accessories to a frame machines’ cleat rails. Fastener bolds (2410) pass through a top plate (2420) then into holes or grooves in an accessory tool’s base (2430) to screw into a cleat (2440) which is secured in locking grooves of a cleat rail (2110, not shown).

[0044] Fig 4B is a perspective view of a cleat fastener’s components. A cleat fastener secures accessory brackets and tools to a frame machine’s cleat rails. Bolts (2410) engage pass-through holes in a top plate (2420), and position in within notches in an accessory tools’ base plate (2430, not shown) before engaging threaded holes in a cleat (2440) that has been fitted to the cleat rails’ (2410, not shown) locking grooves. Cleat fasteners flanking both sides of an accessory tool prevent the bolts from disengaging from the tool’s base plate.

[0045] Fig 5 is a perspective illustration of an above ground wheel ramp attached to a frame machine’s cleat rails to support a vehicle during initial lifting and mounting of the accessory body brackets. An above ground wheel ramp (2700) attaches along the outside of a frame machine’s cleat rail (2110) by engaging a mounting bracket (2709) to the outside locking groove (2120). [0046] In this illustration the mounting bracket (2709) and the support brace (2703) are shown to project below the decking (2705) which is parallel to the top of the cleat rail (2110). A handle (2707) is positioned in the decking (2705) to ease handling of the wheel ramp (2700).

[0047] Fig 6 shows an in-ground wheel tray assembly in accordance with an exemplary embodiment of the invention. An in-ground wheel tray assembly (3000) is comprised of a mounting base or tray support (3010) and an in-ground wheel tray (3030). As the mounting base is positioned in the cleat channel at an angle, the mounting base (3010) has a cleat locking ledge (2013, not visible) on the underneath side which engages the cleat rail in a manner similar to a cleat’s edge. As the mounting base continues to be lowered to a flat orientation allowing the cleat removal curve (3015, not visible) to enter the cleat channel and press against the outer cleat locking groove (2117) securing the mounting base (3010). Cleat fasteners may then be used in the cleat fastener points (3020) to further secure the wheel tray assembly (3000). The wheel tray (3030) has a wheel tray slide pin (3040) which drops down into the mounting base’s (3010) mounting slide (3025). The wheel tray (3030) has an anti-roll curve (3035) along the top side, joining between two ramps (3037).

[0048] Fig 7 shows an illustration of an in-ground wheel tray assembly engaged with a cleat rail of an in-ground mount frame machine positioned to provide maximum ground clearance, in an exemplary embodiment of the innovation. The in-ground wheel tray assembly (3000) comprises the mounting base (3010) engaged with the cleat channel of a cleat rail (2110) sitting at ground level (1200). The wheel tray (3020) is resting on top of the pit wall (1220). With the wheel ramps (3037) and the anti-roll curve (3035) perpendicular to the pit. [0049] Figs 8A - 8C show a series of cross section views illustrating an in-ground wheel tray assembly and the various engagements with the cleat rail of an in-ground frame machine as the frame machine lifts a vehicle in an exemplary embodiment of the innovation.

[0050] Figure8A, shows the wheel tray assembly (3000) positioned on top of the cleat rail (2110) and spanning any gap so the wheel tray (3030) rest directly on the ground level (1200), offering minimal obstacles for loading of low ground clearance vehicle. The cleat locking ledge (3113) and the cleat removal curve (3115) engaged the cleat top rail to secure the wheel tray assembly (3000)

[0051] Figure 8B shows the frame machine beginning to lift, the cleat rail (3110) is inside the wheel track, and the wheel positioned upon the wheel tray (3020), is secured from movement by gravity in the wheel tray’s Anti-roll curve (3035, not visible). The wheel tray’s (3030) slide pin (3040) moves down the mounting base’s (3010) mounting slide (3025) until the wheel tray’s locking ledge (3035) contacts and engages the outside locking groove (2135) of the cleat rail (2110).

[0052] Figure 8C shows the in-ground wheel tray assembly (3020) securely engaged to the cleat rail (2110). It cannot be disengaged until weight is removed from the wheel tray (3020), and the wheel tray (3020) is lifted in the mounting support’s(30l0) mounting slide (3025), then then allows tilting up the distal end of the wheel tray assembly (3020) to disengage the cleat removal curve (3015) and then pulling outward to disengage the cleat locking ledge (3013) and remove the wheel tray assembly (3000) completely from the frame machine (2000). [0053] The diagrams in accordance with exemplary embodiments of the present invention are provided as examples and should not be construed to limit other embodiments within the scope of the invention. For instance, heights, widths, and thicknesses may not be to scale and should not be construed to limit the invention to the specific proportions illustrated. Additionally, some elements illustrated in the singularity may be implemented in a plurality. Further, some element illustrated in the plurality could vary in count. Further, some elements illustrated in one form could vary in detail. Further yet, specific numerical data values (such as specific quantities, numbers, categories, etc.) or other specific information should be interpreted as illustrative for discussing exemplary embodiments. Such specific information is not provided to limit the invention.

[0054] The above discussion is meant to be illustrative of the principles and various

embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.