Abstract: In accordance with exemplary embodiments, methods and systems are provided for providing electrical power for a manufacturing facility for manufacturing of a vehicle, the vehicle having a rechargeable energy storage system (RESS) and a processor, including: positioning the vehicle at the manufacturing facility, the manufacturing facility having an electrical component; and providing electrical power from the RESS of the vehicle to the electrical component of the manufacturing facility, in accordance with instructions provided by the processor.

Abstract: In accordance with exemplary embodiments, methods and systems are provided for providing electrical power for a manufacturing facility for manufacturing of a vehicle, the vehicle having a rechargeable energy storage system (RESS) and a processor, including: positioning the vehicle at the manufacturing facility, the manufacturing facility having an electrical component; and providing electrical power from the RESS of the vehicle to the electrical component of the manufacturing facility, in accordance with instructions provided by the processor.

Abstract: Robotic systems and methods are provided with an end effector having lockable compliance. A robotic system for manipulating a workpiece includes an arm having a pair of sections connected by a joint assembly, with a lock disposed in the joint assembly. A gripper is connected on the arm and is configured to alternately grip and release the workpiece. A controller operates the lock to alternately lock and unlock the joint assembly. The gripper holds the workpiece during a deformation of the workpiece, while the controller may unlock the lock to allow movement of the joint assembly to relieve forces on the arm arising during a deformation of the workpiece.

Abstract: Methods and systems for detecting weld defects, and methods for manufacturing vehicles using such methods or systems, are provided. An exemplary method includes receiving an input indicating a weld material and material thickness by a portable computing device and determining, with the portable computing device, a detection protocol for the weld material and material thickness. Further, the method includes communicating the detection protocol from the portable computing device to a portable heating source and to a portable thermographic sensor, heating a weld with the portable heating source according to the detection protocol, and recording thermographic data from the weld with the portable thermographic sensor according to the detection protocol.

Abstract: In accordance with various embodiments, methods and systems are provided for designing a bead tool and a bead for sheet metal forming. In one embodiment, a method includes: storing, in a datastore, a library of bead tool data associated with a plurality of bead tools; receiving, by a processor, a plurality of parameters associated with at least one of a punch and a die of a desired bead tool; computing, by the processor, bead tool data for at least one of the punch and the die of the desired bead tool based on the plurality of parameters; providing, by the processor, a subset of bead tool data from the library of bead tool data; receiving, by the processor, a selection of bead tool data from the subset of bead tool data and the computed bead tool data; and generating, by the processor, bead geometry data based on the selection and the bead tool data associated with the selection.

Abstract: A multi-component reinforced part forming device includes a forming member having a first side including a wear surface defining a part-shaped cavity, an opposing second side including a protrusion corresponding to the part-shaped cavity, and a peripheral edge. A frame extends about the peripheral edge. The frame includes a first edge arranged adjacent the wear surface and a second edge spaced from the opposing second side. The frame and the opposing second side define a void. A plurality of reinforcing members is arranged in the void. A first number of the plurality of reinforcing members supports the opposing second side and a second number of the plurality of reinforcing members supports the protrusion. An amount of reinforcing backing material is disposed in the void.

Abstract: Systems and methods for bending a material to a target resultant bending parameter using a bend forming tool are disclosed. The systems and methods receive values for parameters of properties of the material and of a bending process to be performed by the bend forming tool, creating or retrieving a calibration curve relating input bending parameter and resultant bending parameter based on the values from a database of calibration curves, determining a first springback compensated input bending parameter based on the target resultant bending parameter using the calibration curve, inputting the first springback compensated input bending parameter to the bend forming tool, and in a first step of bending the material, bending the material to the first springback compensated input bending parameter by applying the bending process using the bend forming tool.

Abstract: Methods and systems for detecting weld defects, and methods for manufacturing vehicles using such methods or systems, are provided. An exemplary method includes receiving an input indicating a weld material and material thickness by a portable computing device and determining, with the portable computing device, a detection protocol for the weld material and material thickness. Further, the method includes communicating the detection protocol from the portable computing device to a portable heating source and to a portable thermographic sensor, heating a weld with the portable heating source according to the detection protocol, and recording thermographic data from the weld with the portable thermographic sensor according to the detection protocol.

Abstract: A system for evaluating a rigidity of an angle bracket includes a test system having a first test fixture and a second test fixture. The system includes an angle bracket coupon including a first wall, a second wall coupled to the first wall at a bend to define an angle between the first wall and the second wall, and at least one three dimensional feature defined at the bend that extends between the first wall and the second wall. The angle bracket coupon is to be coupled to at least one of the first test fixture and the second test fixture to evaluate the rigidity of the angle bracket.

Abstract: Air management systems are provided for optimizing airflow in laser welding with deflectors. A system for a welder includes a blower to generate an airflow stream. A plenum receives the airflow stream, directs it toward the workpiece, and defines an outlet facing the workpiece to expel the airflow stream toward the workpiece. A deflector adjacent the outlet is formed as a conical section converging from the plenum toward the workpiece, and is defined by an angled wall with an open center. The deflector concentrates the airflow stream to impart a velocity increase to the airflow stream after leaving the outlet and to impart a favorable directional component to the airflow stream toward a weld zone, as well as protecting the laser lens by increasing the downward momentum force of the air stream to eliminate the potential of spatter impinging the lens.

Abstract: A method of customizing a vehicle body includes inputting a selected customized embellishment to a laser controller, directing a beam of the laser onto a surface of the vehicle body, and guiding the beam of the laser with the laser controller to impart the selected customized embellishment to the surface.

Abstract: A method for healing surface irregularities in a weld joint includes generating a healing energy beam by a focused energy device, where the healing energy beam includes a predefined energy density. The method also includes scanning the healing energy beam along at least a portion of a periphery of the weld joint, where the weld joint includes at least an upper layer and a lower layer. The method also includes melting less than half a thickness of the upper layer of the weld joint. The predefined energy density of the healing energy beam is based on the thickness of the upper layer of the weld joint.