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 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 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.

Abstract: A system for a work cell having a carrier that moves a product along an assembly line includes an assembly robot, sensor, and controller. An arm of the robot moves on the platform adjacent to the carrier. The sensor measures a changing position of the carrier and encodes the changing position as a position signal. The controller receives the position signal and calculates a lag value of the robot with respect to the carrier using the position signal. The controller detects a requested e-stop of the carrier when the arm and product are in mutual contact, and selectively transmits a speed signal to the robot to cause a calibrated deceleration of the platform before executing the e-stop event. This occurs only when the calculated tracking position lag value is above a calibrated threshold. A method is also disclosed for using the above system in the work cell.

Abstract: A moving stop station includes a vehicle carrier configured to move a vehicle along an assembly line, an assembly platform disposed adjacent to the assembly line, and a synchronizer in communication with the vehicle carrier and the assembly platform. The synchronizer is configured to synchronize the motion of the assembly platform with the motion of the vehicle carrier as the vehicle carrier moves along a length of the assembly line, and includes a sensor, processor, and actuator. The sensor is configured to sense the position of the vehicle carrier and to generate a position signal corresponding to the sensed position. The processor is configured to receive the position signal and selectively provide a synchronization signal in response, and the actuator is configured to receive the synchronization signal and synchronize the motion of the vehicle carrier and the motion of the assembly platform in response.

Abstract: An assembly and method for automated installation of a flexible seal to a periphery of a component. The method may include positioning the periphery of the component adjacent to a seal feed assembly; employing a motor to move the seal toward the periphery of the component until a predetermined torque on the motor is reached; stopping movement of the motor when the predetermined torque is reached; moving the component relative to the seal feed assembly; and, as the component is moved relative to the seal feed assembly, automatically maintaining the predetermined torque in the motor by moving the seal toward the periphery of the component. The component may be a vehicle door to which a seal is installed.

Abstract: A system for a work cell having a carrier that moves a product along an assembly line includes an assembly robot, sensor, and controller. An arm of the robot moves on the platform adjacent to the carrier. The sensor measures a changing position of the carrier and encodes the changing position as a position signal. The controller receives the position signal and calculates a lag value of the robot with respect to the carrier using the position signal. The controller detects a requested e-stop of the carrier when the arm and product are in mutual contact, and selectively transmits a speed signal to the robot to cause a calibrated deceleration of the platform before executing the e-stop event. This occurs only when the calculated tracking position lag value is above a calibrated threshold. A method is also disclosed for using the above system in the work cell.

Abstract: A moving stop station includes a vehicle carrier configured to move a vehicle along an assembly line, an assembly platform disposed adjacent to the assembly line, and a synchronizer in communication with the vehicle carrier and the assembly platform. The synchronizer is configured to synchronize the motion of the assembly platform with the motion of the vehicle carrier as the vehicle carrier moves along a length of the assembly line, and includes a sensor, processor, and actuator. The sensor is configured to sense the position of the vehicle carrier and to generate a position signal corresponding to the sensed position. The processor is configured to receive the position signal and selectively provide a synchronization signal in response, and the actuator is configured to receive the synchronization signal and synchronize the motion of the vehicle carrier and the motion of the assembly platform in response.

Abstract: An assembly and method for automated installation of a flexible seal to a periphery of a component. The method may include positioning the periphery of the component adjacent to a seal feed assembly; employing a motor to move the seal toward the periphery of the component until a predetermined torque on the motor is reached; stopping movement of the motor when the predetermined torque is reached; moving the component relative to the seal feed assembly; and, as the component is moved relative to the seal feed assembly, automatically maintaining the predetermined torque in the motor by moving the seal toward the periphery of the component. The component may be a vehicle door to which a seal is installed.