Abstract: A delivery and assembly system includes a plurality of storage locations including assembly materials and one or more vehicle transports including a controller. The vehicle transports are configured to transport the assembly materials. A control server is communicatively coupled with the controller of the one or more vehicle transports. The control server is configured to identify an available vehicle transport from the one or more vehicle transports and is configured to determine a fitness of the available vehicle transport to receive the assembly materials. An assembly station is configured to receive the available vehicle transport including the assembly materials.

Abstract: A vehicle includes a frame that defines an opening, and a structural panel assembly coupled to the opening. The structural panel assembly includes a first material, a second material opposite the first material, and a third material positioned between the first material and the second material. The third material has an undulating shape that includes a peak and a valley, and the first material is coupled to the peak and the second material is coupled to the valley.

Abstract: A method for manufacturing a structural panel assembly includes providing at least a first material, a second material and a third material positioned between the first material and the second material. The method includes forming the third material to have an undulating shape, and observing, by a sensor, the undulating shape of the third material. The method includes controlling, by a processor, a movement of a welder relative to the first material or the second material based on the observing to weld the first material and the second material to the third material.

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 are provided for configuring a plant assembly station at a vehicle manufacturing plant. Plant sensor data generated by a plant sensor system is received at a plant assembly configuration system. The plant sensor data is associated with a configuration of a first plant assembly station at a vehicle manufacturing plant. A digital twin of the first plant assembly station is generated based in part on the plant sensor data. A determination is made regarding whether the configuration of the first plant assembly station is in accordance with operational regulations based on a simulation-based assessment of the digital twin of the first plant assembly station. An operability status of the configuration of the first plant assembly station is generated based on the determination.

Abstract: Methods and systems are provided that include one or more sensors configured to obtain biometric information as to one or more individuals who are to assist with manufacturing of a vehicle; a non-transitory computer readable storage medium configured to store operational requirements for the manufacturing of the vehicle; and a processor that is configured to at least facilitate providing instructions for creating a swarm ramp on which the vehicle is to be placed in order to provide an ergonomic work envelope for the one or more individuals, based on the biometric information and the operational requirements.

Abstract: A rechargeable energy storage system for a vehicle including a bottom shear plate and a side enclosure having a bottom end connected to the bottom shear plate. A top shear plate is connected to a top end of the side enclosure and a plurality of battery cells are suspended from a bottom of the top shear plate by corresponding mating features that secure the plurality of cells to the top shear plate.

Abstract: A system for joining a first part and a second part together with a weld structure. The system includes: a welding element configured to form the weld structure between the first part and the second part; and a control module configured to operate the welding element to form the weld structure. The weld structure includes: a first curved end; a second curved end; a connecting portion connecting the first curved end and the second curved end; a first curved crown spaced apart from the first curved end and concentric with the first curved end; and a second curved crown spaced apart from the second curved end and concentric with the second curved end. The first curved end, the second curved end, and the connecting portion are between the first curved crown and the second curved crown.

Abstract: Methods and systems are provided for managing vehicle manifest data at a vehicle. Vehicle manifest data is received from a plant operation system at a vehicle manifest data management system of the vehicle. The vehicle manifest data includes a plurality of component identifiers. Each of the component identifiers corresponds to a vehicle component for installation in the vehicle during a vehicle assembly process. The vehicle manifest data includes installation data associated with the installation of each of the vehicle components. A first component identifier associated with a first vehicle component and a first assembly station identifier associated with a first assembly station equipped to install the first vehicle component are received at the vehicle manifest data management system from the plant operation system. The installation data associated with the first vehicle component is transmitted from the vehicle manifest data management system to a station controller of the first assembly station.

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: 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: 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: 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.