Abstract: An automated method for discovering features in a repeatable process includes measuring raw time series data during the process using sensors. The time series data describes multiple parameters of the process. The method includes receiving, via a first controller, the time series data from the sensors, and stochastically generating candidate features from the raw time series data using a logic block or blocks of the first controller. The candidate features are predictive of a quality of a work piece manufactured via the repeatable process. The method also includes determining, via a genetic or evolutionary programming module, which generated candidate features are most predictive of the quality of the work piece, and executing a control action with respect to the repeatable process via a second controller using the most predictive candidate features. A system includes the controllers, the programming module, and the sensors.

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 method includes the following steps: actuating a robotic arm to perform an action at a start position; moving the robotic arm from the start position toward a first position; determining from a vision process method if a first part from the first position will be ready to be subjected to a first action by the robotic arm once the robotic arm reaches the first position; commencing the execution of the visual processing method for determining the position deviation of the second part from the second position and the readiness of the second part to be subjected to a second action by the robotic arm once the robotic arm reaches the second position; and performing a first action on the first part using the robotic arm with the position deviation of the first part from the first position predetermined by the vision process method.

Abstract: An ultrasonic welding system, for welding together two workpieces wherein at least one of the workpieces includes a polymeric composite, comprising an energy applicator positioned along an action axis so that, in operation, ultrasonic vibrations transmitted from the energy applicator during a welding routine, are transmitted to the workpieces generally at and/or adjacent the axis. The system also includes a primary, course-control, actuator positioned along action axis so that a first load, output by the primary actuator, acts along the system action axis. The system further comprises a secondary, fine-control, actuator positioned along the system action axis so that a second load output, by the secondary actuator, acts along the axis. And the system comprises a controller for providing first command signals and second command signals to the primary actuator and second actuator to control them to effect loads on the workpieces, during the welding routine and along the axis.

Abstract: A method for generating a candidate assembly system layout for an assembled product includes inputting a bill of materials including a list of components for the assembled product and determining a plurality of assembly patterns for the assembled product including a plurality of intermediate assemblies and sub-assemblies. A basic task layout is determined that includes assembly tasks for assembling the assembled product based upon a selected one of the assembly patterns. A whole task layout is determined based upon the basic task layout for the selected assembly pattern. Candidate assembly machines are selected for the whole task layout, and zoning constraints are identified for the candidate assembly machines related to assembly tasks. A candidate assembly system layout is generated based upon the whole task layout, the selected candidate assembly machines and the zoning constraints, from which a simulation model of a candidate assembly system is generated.

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 method of forming a conductive adhesive includes condensation-polymerizing a carrier onto a plurality of carbon nanotubes each disposed on a substrate and having a first end and a second end spaced opposite the first end. The carrier is spaced apart from the substrate so that each of the plurality of carbon nanotubes extends continuously through the carrier such that the first end and the second end are spaced apart from the carrier. After condensation-polymerizing, the method includes removing the substrate from the plurality of carbon nanotubes without removing the carrier from the plurality of carbon nanotubes to thereby form the conductive adhesive. A conductive adhesive for removably joining a first surface and a second surface is also disclosed.

Abstract: A thermal-management system, for use in controlling temperature of a first workpiece of workpieces being joined by welding. The system includes a micro heat exchanger including a heat-transfer fluid tube extending between an inlet and an outlet. The system in some implementations has a body and the inlet and outlet are connected to the body. The heat-transfer fluid tube is configured to channel heat-transfer fluid, such as a nanofluid, to heat or cool the workpiece(s). The heat-transfer fluid is configured to cool or heat at least the first workpiece when the heat-transfer fluid is channeled through the heat-transfer fluid-tube section in operation of the thermal-management system. The technology further includes methods and hardware-based controlling apparatus for using the micro heat exchanger to cool or heat the workpieces.

Abstract: A vehicle-battery system including a battery cell and a micro heat exchanger. The micro heat exchanger includes at least one fluid tube positioned in direct contact with the battery cell. The fluid tube comprises a heat-transfer tube section positioned between a fluid tube entrance and exit and in direct contact with the battery cell. The fluid tube is configured to receive a heat-transfer fluid, such a nanofluid, and channel the heat-transfer fluid through the heat-transfer tube section, to the fluid tube exit. The heat-transfer fluid is configured to cool or heat the battery cell when, in operation of the vehicle-battery system, the heat-transfer fluid is channeled through the heat-transfer tube section. The technology in various embodiments also includes a fluid modification device and a computerized controller for controlling the fluid modification device or other operations of the system such as pumping of the heat-transfer fluid.

Abstract: A mechanically conformable micro-heat exchanger for use in managing temperature of a subject component. The exchanger includes a flexible fluid tube. In various embodiments, the tube is connected to a flexible substrate, such as by a flexible polymer. The exchanger can be changed manually from an initial shape to a first shape to conform to a shape of the subject component. The flexible fluid tube is configured to channel heat-transfer fluid through a heat-transfer tube section of the tube. The heat-transfer fluid is configured to cool or heat the subject component when, in operation of the mechanically conformable micro-heat exchanger, the heat-transfer fluid is channeled through the heat-transfer tube section.

Abstract: A thermal-management system, for use in controlling temperature of at least a first workpiece of multiple workpieces being joint. The thermal-management system includes a thermal sleeve sized and shaped to at least partially surround the first workpiece during operation of the thermal-management system. The thermal sleeve comprises a fluid compartment configured to hold heat-transfer fluid, such as nanofluid, for use in heating or cooling the first workpiece during operation of the thermal-management system. In various embodiments, the thermal-management system includes a fixture portion having an elongate channel for affecting temperature by way of heat-transfer fluid passed through the channel. In some embodiments, the thermal-management system includes a heat-transfer fluid bath body for holding heat-transfer fluid to cool or heat workpieces being welded together.

Abstract: Provided is a releasable adhesive system, for joining a first conductive surface and a second conductive surface. The releasable adhesive includes primary material and an embedded material. The primary material includes at least one molecule that is configured to be positioned parallel with at least one molecule of the first conductive surface or the second conductive surface. The embedded material is infused within or affixed to the primary material to form an adhesive structure. The releasable adhesive structure has a conductivity greater than a conductivity of the primary material alone. Also provided is a method for joining the first conductive surface to the second conductive surface using the adhesive structure.

Abstract: A releasable adhesive system for joining a first surface to a second surface. The system includes a primary material having a first portion including at least one first-portion molecule configured to be positioned parallel with at least one first-surface molecule of the first surface, and a second portion, opposite the first portion, including at least one second-portion molecule configured to be positioned parallel with at least second surfaced one molecule of the second surface. The first surface molecule, positioned parallel with the first-surface molecule, is configured to maintain bonds between the first portion and the first surface up to one or more pre-determined force scenarios, such as pre-determined shear, pull, and peel forces being exerted on the first surface. The second portion can function similarly with respect to the second surface. A method is also provided for joining the first surface to the second surface using such releasable adhesive.

Abstract: A method for monitoring and controlling a vibration welding system includes collecting sensory data during formation of a welded joint using sensors positioned with respect to welding interfaces of a work piece. A host machine extracts a feature set from a welding signature collectively defined by the sensory data, compares and correlates the feature set with validated information in a library, and executes a control action(s) when the present feature set insufficiently matches the information. A welding system includes a sonotrode, sensors, and the host machine. The host machine is configured to execute the method noted above.

Abstract: An elastically averaged assembly for closure applications includes a first component comprising at least one receiving feature. Also included is a second component to be repeatedly mated with the first component, the second component comprising at least one protrusion, the at least one receiving feature configured to fittingly receive the at least one protrusion, wherein the at least one protrusion is configured to be repeatedly removed from the at least one receiving feature. The at least one protrusion is formed of an elastically deformable material configured to elastically deform upon contact with the at least one receiving feature.

Abstract: A method includes the following steps: actuating a robotic arm to perform an action at a start position; moving the robotic arm from the start position toward a first position; determining from a vision process method if a first part from the first position will be ready to be subjected to a first action by the robotic arm once the robotic arm reaches the first position; commencing the execution of the visual processing method for determining the position deviation of the second part from the second position and the readiness of the second part to be subjected to a second action by the robotic arm once the robotic arm reaches the second position; and performing a first action on the first part using the robotic arm with the position deviation of the first part from the first position predetermined by the vision process method.

Abstract: An ultrasonic welding system, for welding together two workpieces wherein at least one of the workpieces includes a polymeric composite, comprising an energy applicator positioned along an action axis so that, in operation, ultrasonic vibrations transmitted from the energy applicator during a welding routine, are transmitted to the workpieces generally at and/or adjacent the axis. The system also includes a primary, course-control, actuator positioned along action axis so that a first load, output by the primary actuator, acts along the system action axis. The system further comprises a secondary, fine-control, actuator positioned along the system action axis so that a second load output, by the secondary actuator, acts along the axis. And the system comprises a controller for providing first command signals and second command signals to the primary actuator and second actuator to control them to effect loads on the workpieces, during the welding routine and along the axis.

Abstract: A system includes host and learning machines. Each machine has a processor in electrical communication with at least one sensor. Instructions for predicting a binary quality status of an item of interest during a repeatable process are recorded in memory. The binary quality status includes passing and failing binary classes. The learning machine receives signals from the at least one sensor and identifies candidate features. Features are extracted from the candidate features, each more predictive of the binary quality status. The extracted features are mapped to a dimensional space having a number of dimensions proportional to the number of extracted features. The dimensional space includes most of the passing class and excludes at least 90 percent of the failing class. Received signals are compared to the boundaries of the recorded dimensional space to predict, in real time, the binary quality status of a subsequent item of interest.

Abstract: A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host device, a check station, and a robot. The robot moves the horn and anvil via an arm to the check station. Sensors, e.g., temperature sensors, are positioned with respect to the welding equipment. Additional sensors are positioned with respect to the check station, including a pressure-sensitive array. The host device, which monitors a condition of the welding equipment, measures signals via the sensors positioned with respect to the welding equipment when the horn is actively forming a weld. The robot moves the horn and anvil to the check station, activates the check station sensors at the check station, and determines a condition of the welding equipment by processing the received signals. Acoustic, force, temperature, displacement, amplitude, and/or attitude/gyroscopic sensors may be used.