Abstract: Systems and methods are provided for locating a pair of components relative to one another using complex surfaces. One component has a complex surface, where the complex surface is smoothly contoured. Another component is shaped to be connected with the first component. A fixture locates the first component relative to the second component. The fixture includes a locator with a complex surface region shaped to mate with the complex surface of the one component to locate the fixture relative to that component. The fixture includes another locator to locate the fixture relative to the second component.

Abstract: A vehicle frame inspection and cutting system includes: a frame moving device configured to support a vehicle frame and to transport the vehicle frame; an inspection robot including a first camera configured to capture first images of a side of the vehicle frame; a cutting robot configured to cut holes through vehicle frames and including an identifier disposed on an outer surface of the cutting robot; a second camera disposed vertically above the frame moving device, the inspection robot, and the cutting robot and configured to capture second images vertically downwardly; a control module configured to, based on the first images and the second images: move and actuate the cutting robot and position a cutting tool of the cutting robot at a target location on the vehicle frame; and cut a hole through the vehicle frame at the target location.

Abstract: A power distribution system includes a charging station, a plurality of power socket assemblies, and at least one power line. The charging station includes a charging station control module. The plurality of power socket assemblies are operable to supply power to a vehicle. The at least one power line electrically connects the charging station to each of the plurality of power socket assemblies. The charging station is configured to supply power to any one of the plurality of power socket assemblies through the at least one power line.

Abstract: A system and method of enhanced automated welding of a first workpiece and a second workpiece are provided. The method comprises providing a system for intelligent robot-based welding of the first workpiece and the second workpiece. The method further comprises determining a geometrical location of the first workpiece and the second workpiece to be welded at a welding sequence based a predetermined process variable. The method further comprises adjusting the predetermined process variable based on the geometrical location of the first and second workpieces to define an actual process variable. The method further comprises welding a first portion of the first and second workpieces with the actual process variable to define a first welded portion. The method further comprises determining a weld quality of the first welded portion.

Abstract: A power distribution system includes a charging station, a plurality of power socket assemblies, and at least one power line. The charging station includes a charging station control module. The plurality of power socket assemblies are operable to supply power to a vehicle. The at least one power line electrically connects the charging station to each of the plurality of power socket assemblies. The charging station is configured to supply power to any one of the plurality of power socket assemblies through the at least one power line.

Abstract: A component assembly system comprises a first robot arm having a first end-of-arm tool mounted thereon and adapted to grasp a first subcomponent; a second robot arm having a second end of arm tool mounted thereon and adapted to grasp a second subcomponent. A system controller is adapted to control the first and second robot arms and first and second end-of-arm tools to position the first and second subcomponents relative to one another. A first interlocking mechanism is mounted onto the first end-of-arm tool and a second interlocking mechanism is mounted onto the second end-of-arm tool, wherein the first and second interlocking mechanisms engage one another and lock the first end-of-arm tool to the second end-of arm tool, thereby locking the first and second subcomponents into an initial position relative to one another.

Abstract: A part manufacturing system and a method of manufacturing are provided. The system includes one or more part-moving robots, each having an end effector that grips a part. An operation robot performs an operation on the part while the part-moving robot holds the part. A fixed vision system is located apart from the robots and has at least one fixed vision sensor that senses an absolute location of the part and/or the end effector and generates a fixed vision signal representative of the absolute location. A controller collects the fixed vision signal and compares the absolute location with a predetermined desired location of the part and/or the end effector. The controller sends a repositioning signal to the part-moving robot if the absolute location varies from the predetermined desired location by at least a predetermined threshold, and the part-moving robot is configured to move the part upon receiving the repositioning signal.

Abstract: Systems and methods are provided for locating a pair of components relative to one another using complex surfaces. One component has a complex surface, where the complex surface is smoothly contoured. Another component is shaped to be connected with the first component. A fixture locates the first component relative to the second component. The fixture includes a locator with a complex surface region shaped to mate with the complex surface of the one component to locate the fixture relative to that component. The fixture includes another locator to locate the fixture relative to the second component.

Abstract: A clamp system and method for measurement and control of welding a first substrate to a second substrate is provided. The system comprises a squeeze clamp having to a first end and a second end. The system further comprises a motor connected to the squeeze clamp such that the first and second ends are movable to clamp the first substrate to the second substrate. The system further comprises at least one of an electromagnetic flux sensor, a current sensor, a position sensor, and a gap sensor disposed on one of the first and second ends for determining a first measured variable between the first and second substrates. The system further comprises a controller to control the motor to clamp the first substrate to the second substrate based on the first measured variable. The controller is in communication with the electromagnetic flux sensor, the current sensor, and the gap sensor.

Abstract: A system and method of enhanced automated welding of a first workpiece and a second workpiece are provided. The method comprises providing a system for intelligent robot-based welding of the first workpiece and the second workpiece. The method further comprises determining a geometrical location of the first workpiece and the second workpiece to be welded at a welding sequence based a predetermined process variable. The method further comprises adjusting the predetermined process variable based on the geometrical location of the first and second workpieces to define an actual process variable. The method further comprises welding a first portion of the first and second workpieces with the actual process variable to define a first welded portion. The method further comprises determining a weld quality of the first welded portion.

Abstract: A clamp system and method for measurement and control of welding a first substrate to a second substrate is provided. The system comprises a squeeze clamp having to a first end and a second end. The system further comprises a motor connected to the squeeze clamp such that the first and second ends are movable to clamp the first substrate to the second substrate. The system further comprises at least one of an electromagnetic flux sensor, a current sensor, a position sensor, and a gap sensor disposed on one of the first and second ends for determining a first measured variable between the first and second substrates. The system further comprises a controller to control the motor to clamp the first substrate to the second substrate based on the first measured variable. The controller is in communication with the electromagnetic flux sensor, the current sensor, and the gap sensor.

Abstract: A welding block for a welding system secures together first and second components of a workpiece for a motor vehicle to reduce distortion of the first and second components during a welding process. The welding block includes a jig mechanism that has a proximal surface for receiving a load from an arm of the welding system. The jig mechanism further includes a distal surface for engaging the first component and securing the first and second components to one another during the welding process. The jig mechanism defines a passage, such that heat flows from the distal surface to a coolant flowing through the passage. The welding block further includes a sensor coupled to the jig mechanism for detecting a measured variable associated with at least one of the first and second components.

Abstract: A method of assembling a plurality of subcomponents to form a finished component comprises gripping a first subcomponent with a first end-of-arm tool, wherein the first end-of-arm tool is attached to a first robot arm and grasping a second subcomponent with a second end-of-arm tool, wherein the second end-of-arm tool is attached to a second robot arm. Moving the first and second end-of-arm tools to position the first subcomponent relative to the second subcomponent in a pre-assembly position and then moving the first and second end-of-arm tools to engage interface surfaces of the first and second subcomponents. Forming a joint between the first subcomponent and the second subcomponent with a joining tool attached to a joining robot arm to thereby assemble the finished component.

Abstract: An additive manufacturing system includes a powder delivery system, an area scanning laser, a build chamber, and a controller. The powder delivery system provides a predetermined amount of powder material to the build chamber, and includes a material dispenser, a dispensing head, and a scraper. The scanning laser selectively sinters the powder material, and includes a mirror galvanometer for raster scanning. The build chamber has an annular configuration, and includes an inner annular wall that defines a central portion disposed inward of the build chamber. A portion of the delivery system and the laser are located in the central portion. The chamber continuously rotates under the head and under a sintering zone generated by the laser as the delivery system continuously dispenses the material. The laser continuously raster scans the material at the sintering zone in a raster pattern to sinter a layer of material directly to a preceding layer.

Abstract: A powder bed fusion system includes a plurality of individual build chambers, with each individual build chamber including an area laser scanner optical device and a point laser scanner. A single, area beam delivery system and the plurality of build chambers are moveable relative to each other, such that the area beam delivery system may be positioned to provide an area scanning laser beam to any of the area laser scanner optical devices in any of the plurality of build chambers. The point laser scanners may be used to contour an edge of an object, and the area scanning laser beam may be used to fill in large areas of the object.

Abstract: A method of assembling a secondary component to a primary component comprises grasping a primary component with a first end-of-arm tool, wherein the first end-of-arm tool is attached to a first robot arm and grasping a secondary component with a second end-of-arm tool, wherein the second end-of-arm tool is attached to a second robot arm. Moving the primary component to an interfacing position, wherein interfacing surfaces on the primary component are presented at a proper position and orientation for the secondary component to be attached thereto. Moving the second end-of-arm tool to bring the secondary component into engagement with the interface surfaces of the primary component, and forming a joint between the primary component and the secondary component with a joining tool attached to a joining robot arm.

Abstract: A method of assembling a plurality of subcomponents to form a finished component comprises gripping a first subcomponent with a first end-of-arm tool, wherein the first end-of-arm tool is attached to a first robot arm and grasping a second subcomponent with a second end-of-arm tool, wherein the second end-of-arm tool is attached to a second robot arm. Moving the first and second end-of-arm tools to position the first subcomponent relative to the second subcomponent in a pre-assembly position and then moving the first and second end-of-arm tools to engage interface surfaces of the first and second subcomponents. Forming a joint between the first subcomponent and the second subcomponent with a joining tool attached to a joining robot arm to thereby assemble the finished component.

Abstract: A component assembly system comprises a first robot arm having a first end-of-arm tool mounted thereon and adapted to grasp a first subcomponent; a second robot arm having a second end of arm tool mounted thereon and adapted to grasp a second subcomponent. A system controller is adapted to control the first and second robot arms and first and second end-of-arm tools to position the first and second subcomponents relative to one another. A first interlocking mechanism is mounted onto the first end-of-arm tool and a second interlocking mechanism is mounted onto the second end-of-arm tool, wherein the first and second interlocking mechanisms engage one another and lock the first end-of-arm tool to the second end-of arm tool, thereby locking the first and second subcomponents into an initial position relative to one another.

Abstract: A method of assembling a secondary component to a primary component comprises grasping a primary component with a first end-of-arm tool, wherein the first end-of-arm tool is attached to a first robot arm and grasping a secondary component with a second end-of-arm tool, wherein the second end-of-arm tool is attached to a second robot arm. Moving the primary component to an interfacing position, wherein interfacing surfaces on the primary component are presented at a proper position and orientation for the secondary component to be attached thereto. Moving the second end-of-arm tool to bring the secondary component into engagement with the interface surfaces of the primary component, and forming a joint between the primary component and the secondary component with a joining tool attached to a joining robot arm.

Abstract: Methods and devices for manufacturing paneled structures are provided. The methods include manufacturing a frame structure by additive manufacturing methods and scanning a surface of the frame structure to determine whether there is more than a nominal surface deviation at a location where a panel will be disposed. When there is more than a nominal surface deviation, the methods also include generating a panel to be disposed at the location of the frame structure, wherein the panel has an engagement surface that is complimentary to the surface deviation.