Abstract: An overspray-free paint system includes: a paint robot including an overspray-free paint applicator; and a first fixture robot for lifting and orienting a fixture assembly relative to at least one of the paint robot and the overspray-free paint applicator, the fixture assembly configured to hold an object to be painted by the overspray-free paint applicator, the first fixture robot including a first gripper configured to grab a first portion of the fixture assembly, and the first fixture robot configured to lift and orient the fixture assembly via the first gripper.

Abstract: Systems and methods for changing end-of-arm tools and methods for manufacturing vehicles are provided. An exemplary end-of-arm tool changing system includes a rotatable tool rack configured to hold at least two end-of-arm tools and configured to move a selected end-of-arm tool from a far location to a near location. The exemplary end-of-arm tool changing system further includes a robot configured to reach the near location for attachment of the selected end-of-arm tool to the robot.

Abstract: A compliant end effector includes a robot mounting bracket and a component support member. The component support member includes a side surface and a top surface. A component clamping system includes a first clamp member operable to move toward the side surface of the component support member and a second clamp member operable to move toward the top surface of the component support member. A controller is operatively connected to the clamping system. The controller is configured to engage the first and second clamp members as the component gripping and manipulating system is in a set position and release the first clamp member and the second clamp member allowing a portion of a component held by the component clamping system to move with one or more degrees of freedom when the component gripping and manipulating system is moving to the set position.

Abstract: Systems and methods for changing end-of-arm tools and methods for manufacturing vehicles are provided. An exemplary end-of-arm tool changing system includes a rotatable tool rack configured to hold at least two end-of-arm tools and configured to move a selected end-of-arm tool from a far location to a near location. The exemplary end-of-arm tool changing system further includes a robot configured to reach the near location for attachment of the selected end-of-arm tool to the robot.

Abstract: Methods and systems for assembling components such as for manufacturing vehicles are provided. An exemplary method includes grasping components with assembly robots and determining, with an optic robot, an identity, location, and orientation of each component. Further, the method includes determining a location adjustment and/or an orientation adjustment needed to align the components for joining based on the location and orientation of each component. The method also includes directing a respective assembly robot to move a respective component based on the location adjustment and/or the orientation adjustment to align the components for joining. The method further includes fastening, with a fastening robot, the components to each other to form a joined component.

Abstract: Systems, methods, and apparatuses of a welding system are disclosed and include a first stage of a scanning device for scanning weld parts to generate a three-dimensional (3D) profile of a weld target wherein the 3D profile captures matching imperfections of a meeting together of the set of weld parts when performing the weld operation; and the second stage of a monitoring device to monitor the weld operation and to generate a data of high-resolution measurements of the weld operation; wherein the first stage further includes the monitoring device determining a weld schedule based on the 3D profile, and to adjust the weld schedule while the weld operation progresses to adapt to predicted distortion based on the 3D profile and to sensed distortion; wherein the second stage further includes a plurality of sensors to sense a set of components associated with the weld operation to generate high-resolution data of measurements.

Abstract: Additive manufacturing systems, area scanning laser systems, and methods for performing an additive manufacturing process are provided. An exemplary additive manufacturing system includes a laser generation device for producing a laser beam. Further, the additive manufacturing system includes an optic element for forming a first portion of the laser beam with a first polarization and a second portion of the laser beam with a second polarization different from the first polarization to encode an image in the laser beam. Also, the additive manufacturing system includes a selective beam separator configured to direct the first portion of the laser beam onto a material to be sintered or melted. The additive manufacturing system includes a recycling system for receiving the second portion of the laser beam.

Abstract: A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host machine, a check station, and a welding robot. At least one displacement sensor is positioned with respect to one of the welding equipment and the check station. The robot moves the horn and anvil via an arm to the check station, when a threshold condition is met, i.e., a predetermined amount of time has elapsed or a predetermined number of welds have been completed. The robot moves the horn and anvil to the check station, activates the at least one displacement sensor, at the check station, and determines a status condition of the welding equipment by processing the received signals. The status condition may be one of the alignment of the vibration welding equipment and the wear or degradation of the vibration welding equipment.

Abstract: A part holding assembly, an assembly system and a method of positioning a first part are disclosed. The part holding assembly is coupleable to a support structure. The part holding assembly includes a base adapted to be coupled to the support structure. The part holding assembly also includes a first pin extending outwardly away from the base to a distal end that is spaced from the base. The base is movable to position the first pin relative to a first part and to insert the distal end of the first pin through a first hole of the first part to locate the first part. The part holding assembly further includes a first magnet adjacent to the first pin. The first magnet is selectively magnetized to selectively secure the position of the first part relative to the base.

Abstract: Additive manufacturing systems, area scanning laser systems, and methods for performing an additive manufacturing process are provided. An exemplary additive manufacturing system includes a laser generation device for producing a laser beam. Further, the additive manufacturing system includes an optic element for forming a first portion of the laser beam with a first polarization and a second portion of the laser beam with a second polarization different from the first polarization to encode an image in the laser beam. Also, the additive manufacturing system includes a selective beam separator configured to direct the first portion of the laser beam onto a material to be sintered or melted. The additive manufacturing system includes a recycling system for receiving the second portion of the laser beam.

Abstract: An expanding locating pin assembly configured to locate and hold a part includes a housing, a locating pin, an actuating mechanism, and a controller. The housing is configured with a plurality of radial jaw guides and a part rest face. The locating pin has a plurality of jaws connected to and radially movable in the radial jaw guides and extending past the part rest face. The actuating mechanism synchronously moves the jaws to a radial position and applies a holding force to the part. The controller controls the radial position and the holding force of the jaws. The part rest face of the housing and the jaws of the locating pin are configured to receive the part in a located position. The jaws of the locating pin are configured to hold the part in the located position via the holding force and a friction force resulting from the holding force.

Abstract: A gripping device is described, and includes a holder including a base and a conformable jamming element having an electroadhesive element on a surface thereof and a controllable voltage source that is electrically connected to the electroadhesive element.

Abstract: A method includes receiving, during a vibration welding process, a set of sensory signals from a collection of sensors positioned with respect to a work piece during formation of a weld on or within the work piece. The method also includes receiving control signals from a welding controller during the process, with the control signals causing the welding horn to vibrate at a calibrated frequency, and processing the received sensory and control signals using a host machine. Additionally, the method includes displaying a predicted weld quality status on a surface of the work piece using a status projector. The method may include identifying and display a quality status of a suspect weld. The laser projector may project a laser beam directly onto or immediately adjacent to the suspect welds, e.g., as a red, green, blue laser or a gas laser having a switched color filter.

Abstract: A reconfigurable autonomous workstation includes a multi-faced superstructure including a horizontally-arranged frame section supported on a plurality of posts. The posts form a plurality of vertical faces arranged between adjacent pairs of the posts, the faces including first and second faces and a power distribution and position reference face. A controllable robotic arm suspends from the rectangular frame section, and a work table fixedly couples to the power distribution and position reference face. A plurality of conveyor tables are fixedly coupled to the work table including a first conveyor table through the first face and a second conveyor table through the second face. A vision system monitors the work table and each of the conveyor tables. A programmable controller monitors signal inputs from the vision system to identify and determine orientation of the component on the first conveyor table and control the robotic arm to execute an assembly task.

Abstract: A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host machine, a check station, and a welding robot. At least one displacement sensor is positioned with respect to one of the welding equipment and the check station. The robot moves the horn and anvil via an arm to the check station, when a threshold condition is met, i.e., a predetermined amount of time has elapsed or a predetermined number of welds have been completed. The robot moves the horn and anvil to the check station, activates the at least one displacement sensor, at the check station, and determines a status condition of the welding equipment by processing the received signals. The status condition may be one of the alignment of the vibration welding equipment and the wear or degradation of the vibration welding equipment.

Abstract: A method for locating a first vehicle component relative to a second vehicle component includes the following steps: (a) moving the robotic arm to a first position such that a form feature of the first vehicle component is within a field of view of a camera; (b) capturing an image the form feature of the first vehicle component; (c) moving the robotic arm to a second position such that the form feature of the second vehicle component is within the field of view of the camera; (d) capturing an image of the form feature of the second vehicle component; (e) picking up the second vehicle component using the robotic arm; and (f) moving the robotic arm along with the second vehicle component toward the first vehicle component.

Abstract: A method includes receiving, during a vibration welding process, a set of sensory signals from a collection of sensors positioned with respect to a work piece during formation of a weld on or within the work piece. The method also includes receiving control signals from a welding controller during the process, with the control signals causing the welding horn to vibrate at a calibrated frequency, and processing the received sensory and control signals using a host machine. Additionally, the method includes displaying a predicted weld quality status on a surface of the work piece using a status projector. The method may include identifying and display a quality status of a suspect weld. The laser projector may project a laser beam directly onto or immediately adjacent to the suspect welds, e.g., as a red, green, blue laser or a gas laser having a switched color filter.

Abstract: A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host machine, a check station, and a welding robot. At least one displacement sensor is positioned with respect to one of the welding equipment and the check station. The robot moves the horn and anvil via an arm to the check station, when a threshold condition is met, i.e., a predetermined amount of time has elapsed or a predetermined number of welds have been completed. The robot moves the horn and anvil to the check station, activates the at least one displacement sensor, at the check station, and determines a status condition of the welding equipment by processing the received signals. The status condition may be one of the alignment of the vibration welding equipment and the wear or degradation of the vibration welding equipment.

Abstract: A check fixture measures a total clamp force applied by a welder device. The welder device includes a welding horn having a plurality of weld pads and welding anvil having a plurality of weld pads. The check fixture includes a base member operatively supporting a plurality of force sensors. The base member and the force sensors are received between the weld pads of the welding horn and the anvil pads of the welding anvil. Each force sensor is configured to measure an individual clamp force applied thereto by corresponding weld and anvil pads when the base member is received between the welding horn and the welding anvil and the welder device is in the clamped position. The individual clamp forces are used to determine whether the weld and/or anvil pads are worn or misaligned.

Abstract: A system includes a host machine and a status projector. The host machine is in electrical communication with a collection of sensors and with a welding controller that generates control signals for controlling the welding horn. The host machine is configured to execute a method to thereby process the sensory and control signals, as well as predict a quality status of a weld that is formed using the welding horn, including identifying any suspect welds. The host machine then activates the status projector to illuminate the suspect welds. This may occur directly on the welds using a laser projector, or on a surface of the work piece in proximity to the welds. The system and method may be used in the ultrasonic welding of battery tabs of a multi-cell battery pack in a particular embodiment. The welding horn and welding controller may also be part of the system.