Abstract: In one embodiment, a reconfigurable vehicle interior assembly is provided. The assembly includes a trim member including a plurality of first elastically deformable mating members and a vehicle interior carrier component including a plurality of second elastically deformable mating members. Each of the first elastically deformable mating members matingly engages with at least one of the second elastically deformable mating members in order to couple the trim member to the vehicle interior carrier component. The first and second elastically deformable mating members collectively form a plurality of elastic averaging couplings.

Abstract: A system for assembling a first component and a second component comprises a support operatively supporting the first component without any fixtures, a vision system configured to view the supported first component and the second component and determine the locations thereof, a robotic system configured to move and position the second component relative to the first component, and a controller operatively connected to the vision system and to the robotic system and operable to control the robotic system to position the second component relative to the first component based on the locations determined by the vision system. Various methods of assembling the first component and the second component are provided to create a process joint prior to creation of a structural joint in a subsequent assembly operation.

Abstract: In one embodiment, a reconfigurable vehicle interior assembly is provided. The assembly includes a trim member including a plurality of first elastically deformable mating members and a vehicle interior carrier component including a plurality of second elastically deformable mating members. Each of the first elastically deformable mating members matingly engages with at least one of the second elastically deformable mating members in order to couple the trim member to the vehicle interior carrier component. The first and second elastically deformable mating members collectively form a plurality of elastic averaging couplings.

Abstract: A method can be used to coat a vehicle body. The method includes: (a) providing a metallic substrate; (b) applying a foundation coat over the metallic substrate; (c) applying a basecoat over the foundation coat; (d) applying a clearcoat over the basecoat; and (e) heating the metallic substrate, the foundation coat, the basecoat, and the clearcoat simultaneously in order to cure the foundation coat, the basecoat, and the clearcoat. The foundation coat is inherently UV stable and is configured to protect the vehicle body against corrosion, and bonds the metallic substrate to the basecoat and the clearcoat. A vehicle body includes a metallic substrate, a foundation coat bonded to the metallic substrate, a basecoat disposed over the foundation coat, and a clearcoat disposed over the basecoat.

Abstract: A system includes a host application configured to receive a component model representing a vehicle component. The component model includes a body having a concave portion and/or a convex portion that defines a fluid retainer. A detection tool in communication with the host application is configured to determine a size and location of the fluid retainer. The detection tool is further configured to associate the size of the fluid retainer to a design rule and calculate a value representing a minimum hole size that will allow fluid to flow into or out of the fluid retainer in accordance with the design rule.

Abstract: The disclosure relates to the automatic selection of a set of candidate weld guns and candidate orientations for the weld guns from a library of existing weld guns. Minimum values for weld points and test orientations are calculated. The calculated minimum values are added to the library. As each point is added to the library, the set of weld guns that are candidates for the weld point at the tested orientation may be efficiently retrieved, and a matrix of candidate weld guns and orientations is produced.

Abstract: A process for simulating and assembling flexible parts includes creating an ideal path between first and second planes and placing a virtual rigid envelope around the ideal path, and possibly tubular extensions beyond the path. A virtual flexible part is marked with reference features and pulled through the virtual rigid envelope, such that the path of the virtual flexible part is constrained but may rotate. Removing the virtual rigid envelope allows the virtual flexible part to relax, causing it to move to its lowest energy state. Zero-twist end conditions on the virtual flexible part are marked, corresponding to the intersection of the reference features with the planes. Identification marks are placed on a real flexible part, corresponding to the reference strips on the virtual flexible part. The real flexible part may then be assembled by aligning zero-twist marks on mating features to the identification marks on the real flexible part.

Abstract: A system includes a host application configured to receive a component model representing a vehicle component. The component model includes a body having a concave portion and/or a convex portion that defines a fluid retainer. A detection tool in communication with the host application is configured to determine a size and location of the fluid retainer. The detection tool is further configured to associate the size of the fluid retainer to a design rule and calculate a value representing a minimum hole size that will allow fluid to flow into or out of the fluid retainer in accordance with the design rule.

Abstract: A method to detect and rank appearance distortions includes creating virtual models of a reference panel and a processed panel, including a first reference patch and the processed panel, respectively. Projecting a first simulated light pattern on the reference panel and the processed panel, and viewing the first reference patch and the first processed patch from a first viewpoint with respect to the first simulated light pattern. The method compares a first reference reflection at the first reference patch with a first processed reflection at the first processed patch, and creates a first index value from optical variations between the appearance of the reference and processed reflections. The first index value is output in a computer readable format. The method may compare the first index value to a predetermined index value and determine whether the processed panel is within an acceptable appearance quality threshold.

Abstract: Manufacturing facility process optimization includes monitoring communication signals within a facility device network, analyzing work station specific patterns in the communication signals, developing operational dependencies for work stations based upon the work station specific patterns, and predictively evaluating impacts to the work stations of the proposed configuration of the manufacturing facility process based upon the operational dependencies.

Abstract: A method of weld design for a work piece is provided. The work piece may be a unitary piece or a multi-component piece. The method includes determining a manufacturing feasible region of the work piece satisfying one or more predetermined manufacturing requirements including accessibility of welding components. The method includes determining a performance feasibility function satisfying one or more predetermined performance factors as applied in a performance simulation of the work piece. The workpiece may have a varying number of welds. An optimized weld design may be determined by minimizing an objective function, defined as a summation of the number of welds and the performance feasibility function, within the manufacturing feasible region. The optimized weld design is configured to have a minimum number of welds, and concurrently satisfy the predetermined manufacturing requirements and the performance factors.

Abstract: An apparatus and method of optimizing collision free path planning comprising: initializing a plurality of feasible configuration points, sample points located in a free space, and sample points not located in the free space; determining a goodness rating of the various pluralities of points; generating new candidate points; determining if each new candidate point is a feasible configuration point and adding each to the plurality of feasible configuration points if it is; if not, determining if each new candidate point is located in the free space and adding it to the plurality of sample points located in the free space if it is; if not, adding to the plurality of sample points not located in the free space; determining an updated goodness rating of the various pluralities of points; determining if a termination criteria has been met and reporting a best solution or no solution if it has been met.

Abstract: A method to detect and rank appearance distortions includes creating virtual models of a reference panel and a processed panel, including a first reference patch and the processed panel, respectively. Projecting a first simulated light pattern on the reference panel and the processed panel, and viewing the first reference patch and the first processed patch from a first viewpoint with respect to the first simulated light pattern. The method compares a first reference reflection at the first reference patch with a first processed reflection at the first processed patch, and creates a first index value from optical variations between the appearance of the reference and processed reflections. The first index value is output in a computer readable format. The method may compare the first index value to a predetermined index value and determine whether the processed panel is within an acceptable appearance quality threshold.

Abstract: A process for simulating and assembling flexible parts includes creating an ideal path between first and second planes and placing a virtual rigid envelope around the ideal path, and possibly tubular extensions beyond the path. A virtual flexible part is marked with reference features and pulled through the virtual rigid envelope, such that the path of the virtual flexible part is constrained but may rotate. Removing the virtual rigid envelope allows the virtual flexible part to relax, causing it to move to its lowest energy state. Zero-twist end conditions on the virtual flexible part are marked, corresponding to the intersection of the reference features with the planes. Identification marks are placed on a real flexible part, corresponding to the reference strips on the virtual flexible part. The real flexible part may then be assembled by aligning zero-twist marks on mating features to the identification marks on the real flexible part.

Abstract: Manufacturing facility process optimization includes monitoring communication signals within a facility device network, analyzing work station specific patterns in the communication signals, developing operational dependencies for work stations based upon the work station specific patterns, and predictively evaluating impacts to the work stations of the proposed configuration of the manufacturing facility process based upon the operational dependencies.

Abstract: A method of weld design for a work piece is provided. The work piece may be a unitary piece or a multi-component piece. The method includes determining a manufacturing feasible region of the work piece satisfying one or more predetermined manufacturing requirements including accessibility of welding components. The method includes determining a performance feasibility function satisfying one or more predetermined performance factors as applied in a performance simulation of the work piece. The workpiece may have a varying number of welds. An optimized weld design may be determined by minimizing an objective function, defined as a summation of the number of welds and the performance feasibility function, within the manufacturing feasible region. The optimized weld design is configured to have a minimum number of welds, and concurrently satisfy the predetermined manufacturing requirements and the performance factors.

Abstract: The disclosure relates to the automatic selection of a set of candidate weld guns and candidate orientations for the weld guns from a library of existing weld guns. Minimum values for weld points and test orientations are calculated. The calculated minimum values are added to the library. As each point is added to the library, the set of weld guns that are candidates for the weld point at the tested orientation may be efficiently retrieved, and a matrix of candidate weld guns and orientations is produced.

Abstract: An apparatus and method of optimizing collision free path planning comprising: initializing a plurality of feasible configuration points, sample points located in a free space, and sample points not located in the free space; determining a goodness rating of the various pluralities of points; generating new candidate points; determining if each new candidate point is a feasible configuration point and adding each to the plurality of feasible configuration points if it is; if not, determining if each new candidate point is located in the free space and adding it to the plurality of sample points located in the free space if it is; if not, adding to the plurality of sample points not located in the free space; determining an updated goodness rating of the various pluralities of points; determining if a termination criteria has been met and reporting a best solution or no solution if it has been met.