Abstract: A method of manufacturing a modular vehicle subassembly (MVS) includes assembling a propulsion system onto a vehicle frame, assembling a suspension system onto the vehicle frame, assembling a steering system and braking system onto the vehicle frame, assembling an electrical distribution system onto the vehicle frame, and integrating an onboard controller with the propulsion system, the steering system, and the braking system. The onboard controller is configured to command the propulsion system, the steering system, and the braking system such that the MVS is operable to move untethered through a top hat assembly line during assembly of a top hat on the MVS.

Abstract: A method for verifying an alignment of one or more devices of a vehicle in a manufacturing environment includes selecting an alignment verification routine to be performed by an autonomous alignment verification mobile robot (AAVMR) and autonomously positioning the AAVMR based on a position of the vehicle and one or more displacements associated with the alignment verification routine. The method includes performing, using the AAVMR, the alignment verification routine to generate one or more alignment characteristics associated with the one or more devices and broadcasting a notification based on the one or more alignment characteristics.

Abstract: A method of manufacturing a modular vehicle subassembly (MVS) includes assembling a propulsion system onto a vehicle frame, assembling a suspension system onto the vehicle frame, assembling a steering system and braking system onto the vehicle frame, assembling an electrical distribution system onto the vehicle frame, and integrating an onboard controller with the propulsion system, the steering system, and the braking system. The onboard controller is configured to command the propulsion system, the steering system, and the braking system such that the MVS is operable to move untethered through a top hat assembly line during assembly of a top hat on the MVS.

Abstract: A manufacturing system includes a plurality of first autonomous mobile robots (AMRs), a plurality of second AMRs, and a central management system. Each first AMR transports a body from among multiple bodies for multiple vehicles, and each second AMR transports a chassis from multiple chassis for the multiple vehicles. The central management system is configured to direct the plurality of the first AMRs into a first assembly line process, direct the plurality of the second AMRs into a second assembly line process, and direct an identified second AMR of the plurality of the second AMRs to move behind an identified first AMR of the plurality of the first AMRs. The identified second AMR is transporting a selected chassis from among the plurality of chassis, the identified first AMR is transporting a selected body from among the plurality of bodies, and the selected body is associated with the selected chassis.

Abstract: A manufacturing system includes a plurality of first autonomous mobile robots (AMRs), a plurality of second AMRs, and a central management system. Each first AMR transports a body from among multiple bodies for multiple vehicles, and each second AMR transports a chassis from multiple chassis for the multiple vehicles. The central management system is configured to direct the plurality of the first AMRs into a first assembly line process, direct the plurality of the second AMRs into a second assembly line process, and direct an identified second AMR of the plurality of the second AMRs to move behind an identified first AMR of the plurality of the first AMRs. The identified second AMR is transporting a selected chassis from among the plurality of chassis, the identified first AMR is transporting a selected body from among the plurality of bodies, and the selected body is associated with the selected chassis.

Abstract: A navigation system for remote control movement of modular vehicle subassemblies (MVSs) through a plurality of assembly zones of a vehicle assembly facility includes a predefined primary pathway configured for the MVSs to move along during assembly of top hats on the MVSs, a plurality of sensors, a plurality of zone controllers, and a central management system with a navigation algorithm. The plurality of sensors are configured to transmit at least one of proximity data and visual data on the MVSs moving through the plurality of assembly zones to the plurality of zone controllers. The central management system is configured to be in communication with each of the plurality of zone controllers and the navigation algorithm is configured to receive the at least one of proximity data and visual data and calculate movement instructions for remote control movement of the MVSs moving through the plurality of assembly zones.

Abstract: A method for creating a digital twin for a vehicle assembled on at least one assembly line includes assembly of a modular vehicle subassembly (MVS) in a plurality of MVS assembly zones by assembling at least one component at each MVS assembly zone, scanning the at least one component at each MVS assembly zone and acquiring scanned data, and storing the scanned data in a MVS temporary digital file assigned to the pre-assembled MVS. The method also includes updating a MVS permanently digital file assigned to the pre-assembled MVS after the at least one component at each of the MVS assembly zones has been assembled and storing the MVS permanent digital file when assembly of the MVS is complete.

Abstract: A method for verifying an alignment of one or more devices of a vehicle in a manufacturing environment includes selecting an alignment verification routine to be performed by an autonomous alignment verification mobile robot (AAVMR) and autonomously positioning the AAVMR based on a position of the vehicle and one or more displacements associated with the alignment verification routine. The method includes performing, using the AAVMR, the alignment verification routine to generate one or more alignment characteristics associated with the one or more devices and broadcasting a notification based on the one or more alignment characteristics.

Abstract: A system for remote control of modular vehicle subassemblies within a vehicle assembly facility includes a central management system having predetermined assembly paths and specifications for the modular vehicle subassemblies and a zone management system having zone controllers in communication with the central management system and in communication with the onboard controllers of the modular vehicle subassemblies. The zone controllers are configured to receive transient data from the onboard controllers of the modular vehicle subassemblies and manage movement of the modular vehicle subassemblies throughout the zones within the vehicle assembly facility.

Abstract: A task managing system for testing and configuring one or more vehicles includes a plurality of task execution controllers. Each of the plurality of the task execution controllers defines a set of communication nodes configured to wirelessly communicate with a set of vehicles of a plurality of vehicles. The task execution controller includes a processor configured to execute instructions stored in a nontransitory computer-readable medium to operate as a task application module configured to execute a task order on a selected vehicle from the set of vehicles by way of a selected communication node from the set of communication nodes.

Abstract: A method includes positioning, by a robot, a servo press proximate one or more reference identifiers of the vehicle. The method includes applying, by the servo press, a known weight to the vehicle. The method includes calibrating the payload monitoring system of the vehicle based on data from a plurality of payload sensors in response to applying the known weight.

Abstract: A manufacturing system includes a first autonomous mobile robot (AMR), a second AMR, a first set of mobile robotic systems, and a central management system. The first AMR transports a body of a vehicle to an assembly area. The second AMR transports a chassis of the vehicle to the assembly area. The first set of mobile robotic systems is provided at the assembly area and moves the body. The central management system includes instructions to direct the first AMR transporting the body to the assembly area; direct the second AMR transporting the chassis to the assembly area; have the first set of mobile robotic systems lift the body from the first AMR; direct the first AMR to a secondary area; direct the second AMR to move to a desired position relative to the body; and instruct the first set of mobile robotic systems place the body on the chassis.

Abstract: An automatic parts delivery system includes a controller, fleets of robots, an autonomous storage-retrieval system and workstations. The controller monitors inventory state of automotive parts during a selected block of time and identifies unavailability of parts for manufacturing a selected vehicle model. The controller determines whether remaining parts can be used to manufacture another vehicle model. The fleets of robots scan, deliver and sort parts and prepare a custom kit including at least the remaining parts. The custom kit is delivered to produce another vehicle model at the workstations for producing the selected vehicle model or another vehicle model.

Abstract: A method includes positioning, by a robot, a servo press proximate one or more reference identifiers of the vehicle. The method includes applying, by the servo press, a known weight to the vehicle. The method includes calibrating the payload monitoring system of the vehicle based on data from a plurality of payload sensors in response to applying the known weight.

Abstract: A system for remote control of modular vehicle subassemblies within a vehicle assembly facility includes a central management system having predetermined assembly paths and specifications for the modular vehicle subassemblies and a zone management system having zone controllers in communication with the central management system and in communication with the onboard controllers of the modular vehicle subassemblies. The zone controllers are configured to receive transient data from the onboard controllers of the modular vehicle subassemblies and manage movement of the modular vehicle subassemblies throughout the zones within the vehicle assembly facility.

Abstract: A navigation system for remote control movement of modular vehicle subassemblies (MVSs) through a plurality of assembly zones of a vehicle assembly facility includes a predefined primary pathway configured for the MVSs to move along during assembly of top hats on the MVSs, a plurality of sensors, a plurality of zone controllers, and a central management system with a navigation algorithm. The plurality of sensors are configured to transmit at least one of proximity data and visual data on the MVSs moving through the plurality of assembly zones to the plurality of zone controllers. The central management system is configured to be in communication with each of the plurality of zone controllers and the navigation algorithm is configured to receive the at least one of proximity data and visual data and calculate movement instructions for remote control movement of the MVSs moving through the plurality of assembly zones.

Abstract: A method for creating a digital twin for a vehicle assembled on at least one assembly line includes assembly of a modular vehicle subassembly (MVS) in a plurality of MVS assembly zones by assembling at least one component at each MVS assembly zone, scanning the at least one component at each MVS assembly zone and acquiring scanned data, and storing the scanned data in a MVS temporary digital file assigned to the pre-assembled MVS. The method also includes updating a MVS permanently digital file assigned to the pre-assembled MVS after the at least one component at each of the MVS assembly zones has been assembled and storing the MVS permanent digital file when assembly of the MVS is complete.

Abstract: A modular vehicle subassembly includes a frame assembly with wheels and a steering system configured to steer at least one of the wheels and change a course of direction of the frame assembly. A propulsion system configured to drive at least one of the wheels and move the frame assembly in at least one of a forward direction and a backward direction is included. At least one transient data sensor, an onboard controller, and an onboard communications link are included and the least one transient data sensor is coupled is configured to detect and transmit transient data. The onboard controller is configured to receive the transient data from the at least one transient data sensor, direct the steering system and the propulsion system such that the frame assembly moves along a predefined path through a flexible modular platform facility.

Abstract: A facility-based sensory system for the manufacture of modular vehicle subassemblies (MVSs) includes facility-based sensors and zone controllers. Each of the facility-based sensors is configured to be in communication with and transmit proximity data and/or vision data to the zone controllers. And each of the zone controllers is configured to be assigned to one of a plurality of assembly zones along an assembly line such that a MVS moving through the plurality of assembly zones is detected by the plurality of facility-based sensors and the detection is transmitted to the plurality of zone controllers. An onboard controller is included and configured to be attached to the MVS moving through the plurality of assembly zones. The onboard controller is configured to receive instructions from the plurality of zone controllers such that monitoring and directing of the MVS moving through the plurality of assembly zones is provided.

Abstract: A method of manufacturing a modular vehicle subassembly (MVS) includes assembling a propulsion system onto a vehicle frame, assembling a suspension system onto the vehicle frame, assembling a steering system and braking system onto the vehicle frame, assembling an electrical distribution system onto the vehicle frame, and integrating an onboard controller with the propulsion system, the steering system, and the braking system. The onboard controller is configured to command the propulsion system, the steering system, and the braking system such that the MVS is operable to move untethered through a top hat assembly line during assembly of a top hat on the MVS.