Abstract: A method of inverting workpieces in a mass production process includes: advancing an end effector in electronic synchronization with advancement of a carrier to synchronize arrival of the carrier at a stop position with arrival of the end effector at an unloading position, in which the end effector is in alignment with a workpiece held by the carrier for engaging the workpiece; while the end effector is in engagement with the workpiece, retracting the end effector away from the carrier to unload the workpiece from the carrier and advancing the end effector back toward the carrier to load the workpiece back into the carrier; and rotating the end effector relative to the carrier to invert the workpiece in electronic synchronization with the retracting and advancing of the end effector for loading the workpiece back into the carrier when inverted.

Abstract: There is described systems and methods for programming and configuring part-processing devices and production stations. Methods of programming the control system of a part-processing device for controlling one or more tooling components, sensors and/or motion systems includes the step of loading a software backplane onto the control system, the software backplane being configured to run on an operating system of the control system and to interface with one or more configurable applications. The method also comprises the step of loading one or more configurable applications associated with the one or more tooling components onto the control system, the one or more applications being configured to interface with the software backplane. The method also comprises the step of configuring the one or more configurable applications to control the one or more tooling components, sensors and/or motion systems pf the part-processing device.

Abstract: A method of inverting workpieces in a mass production process includes: advancing an end effector in electronic synchronization with advancement of a carrier to synchronize arrival of the carrier at a stop position with arrival of the end effector at an unloading position, in which the end effector is in alignment with a workpiece held by the carrier for engaging the workpiece; while the end effector is in engagement with the workpiece, retracting the end effector away from the carrier to unload the workpiece from the carrier and advancing the end effector back toward the carrier to load the workpiece back into the carrier; and rotating the end effector relative to the carrier to invert the workpiece in electronic synchronization with the retracting and advancing of the end effector for loading the workpiece back into the carrier when inverted.

Abstract: A method of processing O-rings in an automated mass production system includes: (a) advancing an O-ring retainer toward a loading position in alignment with an output end of a feed device; (b) discharging a leading O-ring from the output end in electronic synchronization with advancement of the O-ring retainer to the loading position to initiate loading of the O-ring into the retainer prior to the retainer arriving at the loading position; (c) after loading the O-ring into the retainer, advancing the retainer away from the loading position toward an unloading position; and (d) moving an end effector in electronic synchronization with advancement of the retainer to the unloading position to synchronize arrival of the retainer at the unloading position with arrival of the end effector at a pick-up position in alignment with the O-ring at the unloading position for pick up of the O-ring by the end effector.

Abstract: Methods and systems are provided for mass producing different products in an automated production station having a plurality of part-processing devices. An example method includes identifying a workpiece received in the production station; selecting control parameters associated with the identified workpiece; electronically synchronizing the part-processing devices based on the selected control parameters to perform coordinated operations on the workpiece for producing one of the different products; and automatically repeating the identifying, selecting, and synchronizing steps for different workpieces received in the production station to produce a plurality of different products in a continuous mass production process.