The push to get vehicles through the pipeline faster has led to changes that make frame machines more versatile and cost-effective for today's collision repairers
Straightening techniques continue to evolve as automotive construction changes. Though the basic structural repair theories such as "last in, first out" and "returning a vehicle to its original shape and state" remain constant, the way technicians meet repair objectives also continues to evolve.So what are these changes? They include ease and speed of mounting, and new or changing mounting locations. Also changing are the areas of measuring ease and accuracy, and pulling options.
As shops face additional pressures to reduce cycle times, it's vital for today's structural repairs to be completed as rapidly as possible. This means vehicles must be mounted and anchored as quickly as possible. Anchoring devices must be versatile enough to easily adapt to damaged vehicles and to hold them safely as pulling or pushing pressure is applied.
As vehicle construction evolves and traditional rocker pinch-weld locations change, anchoring clamps must also evolve with them. Some new solutions are suspension-mounting locations (Fig. 1), and inside door mounting locations (Fig. 2). Mounting devices also must be versatile enough to adapt to damaged vehicles. This means they must be free to move to meet altered mounting locations due to collision damage (Fig. 3).Speed and ease of mounting is changing as well. Shops no longer have the luxury of taking hours to mount damaged vehicles to machines. They must be mounted easily and quickly to provide access to mechanical parts that may need to be removed. Easy access for technicians also should be taken into consideration. For example, if a machine is moved to different heights, the technician can easily work at a convenient level, thus speeding up the repair process.
As shop management techniques change and more shops adapt the theory of moving a technician to the vehicle, as opposed to moving the vehicle to the technician, movable structural repair equipment becomes important as well. Having movable structural repair equipment eliminates a fixed "frame bench," a space that is only used for frame repairs, which is not profitable, and if a technician or teams of technicians are moved to the vehicle, wasted non-profitable time can be eliminated.Measuring options have also changed. With the development of computerized measuring solutions, technicians can now accurately assess the direction and extent of damage sustained by a vehicle. Measuring devices have not only taken under measurement; upper body and opening measurements are also available to technicians to confirm the accuracy of a repair. It is no longer necessary to fit sheet metal to the vehicle to judge if it has been returned to its original state, then "adjusting" it to make it fit, and it is no longer the method of choice. When the vehicle has been returned to its proper specifications, parts can be assembled with confidence, with "adjustment" no more complex than that needed when it was manufactured.
Measuring equipment setup is no longer the time-consuming, complex process it once was, either. User-friendly computerized measuring systems that do not need to be removed if further pulling is necessary have become common. The ability of computers to save or generate documents of the repair process has also improved over the years. We can now verify what the original damage was and how it was corrected, thus making recordkeeping more complete.With multiple pulling devices, it is common to be able to pull, push and hold simultaneously, which allows a technician to precisely locate the repair pressures. Therefore, less pressure is used to accomplish what once required large amounts of pressure. Pulling in an overhead direction is no longer a cumbersome and time-consuming process (Fig. 4).
"Throughout the years, the auto body repair industry has seen quite an evolution concerning the development and use of frame machines," says Fred Nicholson, vice president of sales for the Collision Equipment Group. "Starting with a rope tied between the old oak tree and the damaged vehicle, to high-powered pulling platforms providing multiple pulling capabilities."
According to Jim Wrigley, a trainer for Chief Automotive Technologies, one of the most significant changes in repair techniques in the last years is "multiple pull" capability. Not only does multiple pull give you the precision for repairing deep damage, but it also causes less damage during the process. Before the use of multiple pull was available to technicians, pulling on a single location often caused more or as much damage as it repaired. With multiple pull, the pressure in a single location is decreased and less ripping is caused by the pulling location.Jeff Syvrud, vice president of sales and marketing for Chassis Liner, has seen today's frame racks getting longer and wider than those of the past. This gives technicians the ability to pull anything, from larger SUV/crew cab pickup trucks to smaller unibody vehicles.
"The equipment today is more versatile with wheelless towers and 360-degree pulling capabilities, versus floor-type systems," says Syvrud.
Syvrud adds that many insurers now require shops to have drive-on frame racks in order to meet direct repair program business requirements."Years ago, most shops couldn't afford a frame machine priced over $25,000," he says. "Today, a small shop can purchase a new frame machine for under $10,000 and keep the business in-house."
Another recent trend in structural repair is "microsurgery," says Tuomo Lehtovirta of Autorobot Finland Oy.
"With simultaneous pull/push technology and adequate support, it is possible to straighten only the damaged part of the vehicle," says Lehtovirta. "The undamaged part is kept in position, meanwhile repairing the damaged parts."
During "microsurgery" access holes (22 mm) are drilled (Fig. 5) and the microsurgery pull-push device is attached (Fig. 6), allowing technicians to perform precise repairs. Access holes are covered following the straightening process (Fig. 7)."Microsurgery eliminates unnecessary work," says Lehtovirta. "Time used is minimized, bringing an increased return on the investment."
Another significant straightening technique change is the integration of bench and fixture straightening tools. Technicians previously were asked to choose between the ease and versatility of bench-type repair benches and the go/no-go preciseness and simplicity of a fixture bench. Repair equipment has now evolved to where some equipment provides the use of universal fixtures on a bench-type system (Fig. 8).When structural parts are removed and new ones are fit-up for replacement, they are held in place by jigs. This allows a technician to attach parts with confidence that they will be placed in precisely the correct location.
Mike Houston, director of market development for Celette North America, says when the first unibody vehicles appeared in the 1960s, racks were modified. Instead of chains, clamps were used to hold a vehicle at four points, and damage was pulled out.
However, little research has been done showing that a unibody vehicle held in only four places will respond accurately to pulling forces applied at the extremities of the vehicle, says Houston.
"Some vehicle manufacturers — BMW and Mercedes-Benz — have stated that pinch weld clamps or jack support areas are not to be used for anchoring during pulling operations," he says. "If this warning is not heeded, severe damage can occur."
On the other hand, Houston says systems with dedicated fixtures hold all undamaged points in place, and as damaged areas are pulled back into place and more fixtures are added to newly corrected points, these become additional support and anchoring locations.
"The anchoring forces are distributed across the entire body shell, while the pulling forces are localized," Houston says. "The result is that fewer parts need to be replaced, and no pulling forces deform undamaged areas of the vehicle."
So what else should a shop look for when purchasing frame straightening equipment? One consideration is the type of work it is performing. According to Nicholson, if minor straightening of front rails for proper alignment of bumper supports is the requirement, then floor systems and a work platform should be considered. If full frame or unibody corrections to factory specifications are to be completed, then a platform with multiple pulling capability is required.
"Another consideration should be whether or not your existing equipment works with the new system," says Nicholson. "Will your measuring system compliment the system? Do you have the necessary air pressure capacity and electricity required? And don't forget to make sure you have the proper lighting."
Nicholson also says to consider the amount of space that the equipment will take up in the shop and the training that will be provided with the purchase.
"Find out if training can be performed in the shop or if you'll have to send your technicians somewhere," says Nicholson. "Will all of the technicians be trained or only one? What about the warranty and what is covered? And where is the representative located?"
Straightening techniques have developed significantly, and push, pull and hold operations continue to evolve. Multiple pulling techniques are becoming easier, reducing cycle time. Benches are adapting to changing conditions by being more mobile or more versatile, so workspace is better used as machines adapt to workforce ease.
Overhead pulling has become easier, machines can be operated with cordless remotes, fixtures have been adapted to bench equipment, and companies are working on "microsurgery" techniques.
Change is constant, and as automobile construction changes, so will straightening techniques.
