Abstract: A method for joining a plurality of workpieces includes providing a rotating drive tool. A fastener is secured to the drive tool. The drive tool is then rotatably driven such that a distal end of the fastener rotates against a surface of the plurality of workpieces. A heated material zone is then generated on the plurality of workpieces as caused by friction from the rotation of the fastener against the surface of the plurality of workpieces. The distal end of the fastener is rotatably and axially driven through the heated material zone. Finally, the drive tool is removed from the fastener, such that when the heated material zone cools, a portion of the heated material zone is fused to the fastener.

Abstract: A method of forming a layer on a first component according to various aspects of the present disclosure includes melting a portion of a first metallic composition of the first component. The melting includes directing a laser beam toward a first surface of the first component. The method further includes depositing a second metallic composition on the first surface by directing a precursor including the second metallic composition toward an intersection of the first surface and the laser beam. The second metallic composition is galvanically more noble than the first metallic composition. The method further includes forming the layer on the first component by solidifying the first metallic composition and the second metallic composition. The first component is configured to be joined to a second component by engaging a plurality of micro-anchors defined on the layer with a polymer of the second component.

Abstract: The present disclosure provides a metal-polymeric composite joint including a first component and a second component. The first component includes a metal. The first component has a first surface including a plurality of micro-anchors. The second component includes a composite material including a polymer and a reinforcing fiber. The second component has a second surface that at least partially engages the first surface of the first component. A portion of the polymer of the second component occupies at least a portion of the micro-anchors of the first component to fix the second component to the first component. In one aspect, the metal-polymeric composite joint further includes a passivation layer disposed between the first surface of the first component and the second surface of the second component.

Abstract: A method for laser welding of non-transmissive composite materials includes: forming an energy channel having an end opening and extending through a first part made of a first material; and welding a second part made of a second material to the first part via laser heating of the materials of the first and second parts proximate to the end opening of the energy channel such that the materials of the first and second parts fuse to form a weld nugget, attaching the first part to the second part.

Abstract: A resistance spot welding method can be used to join polymeric and metallic workpieces together and includes the following steps: (a) placing an electrically conductive coating between a polymeric workpiece and a metallic workpiece, wherein the metallic workpiece has a textured surface facing the polymeric workpiece; (b) piercing the polymeric workpiece with first and second electrically conductive pins of a welding electrode assembly; (c) applying electrical energy to the first and second electrically conductive pins so that an electrical current flows through the first electrically conductive pin, the electrically conductive coating, and the second electrically conductive pin in order to at least partially melt the polymeric workpiece and the electrically conductive coating, thereby forming a weld pool; and (d) cooling the weld pool to form a solid weld nugget in order to establish a mechanical interface lock between the solid weld nugget and the textured surface.

Abstract: A method for joining a plurality of workpieces includes providing a rotating drive tool. A fastener is secured to the drive tool. The drive tool is then rotatably driven such that a distal end of the fastener rotates against a surface of the plurality of workpieces. A heated material zone is then generated on the plurality of workpieces as caused by friction from the rotation of the fastener against the surface of the plurality of workpieces. The distal end of the fastener is rotatably and axially driven through the heated material zone. Finally, the drive tool is removed from the fastener, such that when the heated material zone cools, a portion of the heated material zone is fused to the fastener.

Abstract: A resistance spot welding system can join two polymeric workpieces and includes a power supply. The power supply has a positive terminal and a negative terminal. The resistance spot welding system further includes a welding electrode assembly electrically connected to the power supply. The welding electrode assembly includes a housing, a first electrically conductive pin and a second electrically conductive pin. The first and second electrically conductive pins both protrude from the housing. The first electrically conductive pin is electrically connected to the positive terminal of the power supply, and the second electrically conductive pin is electrically connected to the negative terminal of the power supply. The second electrically conductive material is electrically insulated from the first electrically conductive pin. The first and second electrically conductive pins are at least partly made of a material having a hardness ranging between 50 HRC and 70 HRC.

Abstract: A resistance spot welding method can be used to join polymeric and metallic workpieces together and includes the following steps: (a) placing an electrically conductive coating between a polymeric workpiece and a metallic workpiece, wherein the metallic workpiece has a textured surface facing the polymeric workpiece; (b) piercing the polymeric workpiece with first and second electrically conductive pins of a welding electrode assembly; (c) applying electrical energy to the first and second electrically conductive pins so that an electrical current flows through the first electrically conductive pin, the electrically conductive coating, and the second electrically conductive pin in order to at least partially melt the polymeric workpiece and the electrically conductive coating, thereby forming a weld pool; and (d) cooling the weld pool to form a solid weld nugget in order to establish a mechanical interface lock between the solid weld nugget and the textured surface.

Abstract: A resistance spot welding system can join two polymeric workpieces and includes a power supply. The power supply has a positive terminal and a negative terminal. The resistance spot welding system further includes a welding electrode assembly electrically connected to the power supply. The welding electrode assembly includes a housing, a first electrically conductive pin and a second electrically conductive pin. The first and second electrically conductive pins both protrude from the housing. The first electrically conductive pin is electrically connected to the positive terminal of the power supply, and the second electrically conductive pin is electrically connected to the negative terminal of the power supply. The second electrically conductive material is electrically insulated from the first electrically conductive pin. The first and second electrically conductive pins are at least partly made of a material having a hardness ranging between 50 HRC and 70 HRC.

Abstract: Provided is a system and a method for identifying inefficiency of energy utilization in a facility by using actual past consumption data. The method uses the past energy usage data, weather information, production information, and variables estimated using Stochastic Frontier equation to calculate energy inefficiency for a production facility.

Abstract: A method for generating an electronic work order for plant maintenance includes detecting a fault of a machine in the plant, and communicating fault information to a system. The system has a server and a database for recording downtime of the machine. The method further includes generating the work order via the server in response to the fault, including recording, within in the work order, a plurality of values from the fault information. The work order is transmitted from the server to a computing device, and a confirmation signal is recorded by the computing device indicating completion of the repair. The method includes transmitting a completed work order from the computing device to the server and recording the completed work order in the database. A system is also disclosed for generating an electronic work order for maintenance in a plant. The system includes the database and server noted above.

Abstract: Disclosed herein are a system, method and apparatus for reporting, making alerts and predicting fault codes generated by machines in a line. Historical fault code data is received and filtered according to particular criteria to generate filtered fault code data. Classification of the filtered fault code data into physical groups and into logical groups is followed by sorting the groups to produce fault trend data. Processing the fault trend data with a plurality of analyzers generates output including reports, alerts, and predictions of future fault code occurrences.

Abstract: A costing process that takes advantage of real-time information about plant floor activities and provides a more accurate and timely financial feedback about the process efficiencies in response to new changes in the process operation. The costing process includes identifying stations that consume resources, consume activities and supply activities. The costing process also identifies a plurality of resources that are provided to one or more of the stations. The costing process also includes identifying resources from the plurality of resources that are used as needed and resources that are supplied in advance of being used. The costing process allocates costs for each resource to each station that the resource supplies, including calculating a cost rate, calculating a cost of used capacity and calculating a cost of unused capacity. The costing process then determines the cost that each station and product uses based on the allocations.

Abstract: Methods, systems, and computer program products for controlling production systems. Methods include monitoring actual performance of a production system that includes a plurality of machines. The actual performance of the production system is compared to a planned level of performance of the production system. One or more short-term production constraints in the production system are identified in response to the actual performance being more than a threshold value away from the planned level of performance. A corrective action for the production system is determined to mitigate one or more of the short-term production constraints. The corrective action is applied to the production system.

Abstract: A system and method for data analysis are disclosed. Data analysis may include a step of filtering the data to produce filtered data. The method may include processing a plurality of prediction algorithms to produce prediction values, the prediction values having associated historical and expected prediction confidence intervals. The method may also include evaluating performance of the prediction algorithms to generate performance indexes, the performance indexes having associated index confidence intervals. The method may also include generating relevance values of the prediction algorithms based on the performance indexes, and index confidence intervals. The method may further include applying the relevance values and prediction confidence intervals to determine how to combine prediction values, and applying multivariable data fusion to combine the prediction values.

Abstract: A method for determining whether to provide automatic reset instructions to a machine with reset capability with respect to a fault code event, the method comprising, in a database, collecting records comprising the identification of the machine, a fault code associated therewith and the duration of a fault associated with the fault code that the machine experienced within a time period, and performing a statistical analysis on the records to analyze whether executing an automatic reset on the machine with respect to the fault code will probabilistically rectify the fault and to generate resultant data.

Abstract: A method and system of automatically curve fit data series to generate data signal characterization and prediction is disclosed. The method includes receiving input data including a plurality of data series and set of input parameters. The method also includes preprocessing the data series to generate preprocessed data according to a plurality of input parameters. The method further includes performing sorting and prioritization of the data series and curve fitting by a plurality of models and search and optimization algorithms on the smoothed or raw data series according to a plurality of input parameters to generate text and graphic output, and storing text and graphic output. The system includes modules for carrying out steps of the method.

Abstract: A system and method for data analysis are disclosed. Data analysis may include a step of filtering the data to produce filtered data. The method may include processing a plurality of prediction algorithms to produce prediction values, the prediction values having associated historical and expected prediction confidence intervals. The method may also include evaluating performance of the prediction algorithms to generate performance indexes, the performance indexes having associated index confidence intervals. The method may also include generating relevance values of the prediction algorithms based on the performance indexes, and index confidence intervals. The method may further include applying the relevance values and prediction confidence intervals to determine how to combine prediction values, and applying multivariable data fusion to combine the prediction values.

Abstract: Methods, systems, and computer program products for controlling production systems. Methods include monitoring actual performance of a production system that includes a plurality of machines. The actual performance of the production system is compared to a planned level of performance of the production system. One or more short-term production constraints in the production system are identified in response to the actual performance being more than a threshold value away from the planned level of performance. A corrective action for the production system is determined to mitigate one or more of the short-term production constraints. The corrective action is applied to the production system.

Abstract: A method and system of automatically curve fit data series to generate data signal characterization and prediction is disclosed. The method includes receiving input data including a plurality of data series and set of input parameters. The method also includes preprocessing the data series to generate preprocessed data according to a plurality of input parameters. The method further includes performing sorting and prioritization of the data series and curve fitting by a plurality of models and search and optimization algorithms on the smoothed or raw data series according to a plurality of input parameters to generate text and graphic output, and storing text and graphic output. The system includes modules for carrying out steps of the method.