Abstract: Methods for manufacturing structures are provided. The methods include manufacturing a shell structure by additive manufacturing methods and sectioning panels with predetermined shapes from the shell structure. The panels are subsequently coupled to shell structure. Devices for performing various steps of the methods are also provided.

Abstract: A method for joining a plurality of workpieces includes providing a rotating drive tool. A fastener is secured to the drive tool. The drive tool is then rotatably driven such that a distal end of the fastener rotates against a surface of the plurality of workpieces. A heated material zone is then generated on the plurality of workpieces as caused by friction from the rotation of the fastener against the surface of the plurality of workpieces. The distal end of the fastener is rotatably and axially driven through the heated material zone. Finally, the drive tool is removed from the fastener, such that when the heated material zone cools, a portion of the heated material zone is fused to the fastener.

Abstract: An automated guided vehicle system may include a plurality of automated guided vehicles arranged in a predetermined relationship with respect to each other for supporting a payload. Each of the automated guided vehicles has a plurality of rollers extending from the automated guided vehicle and engaging a ground surface. Furthermore, at least one locator extends from the automated guided vehicle and engages the payload. Each of the automated guided vehicles also has an on-board controller arranged within a housing thereof, with one on-board controller acting as a master controller and the remaining of the on-board controllers acting as slave controllers. The master controller communicates with the slave controllers to maintain position and speed control of each automated guided vehicle in both a lateral and a longitudinal direction. Furthermore, the slave controllers send feedback information to the master controller.

Abstract: An automated guided vehicle system may include a plurality of automated guided vehicles arranged in a predetermined relationship with respect to each other for supporting a payload. Each of the automated guided vehicles has a plurality of rollers extending from the automated guided vehicle and engaging a ground surface. Furthermore, at least one locator extends from the automated guided vehicle and engages the payload. Each of the automated guided vehicles also has an on-board controller arranged within a housing thereof, with one on-board controller acting as a master controller and the remaining of the on-board controllers acting as slave controllers. The master controller communicates with the slave controllers to maintain position and speed control of each automated guided vehicle in both a lateral and a longitudinal direction. Furthermore, the slave controllers send feedback information to the master controller.

Abstract: Methods for manufacturing structures are provided. The methods include manufacturing a shell structure by additive manufacturing methods and sectioning panels with predetermined shapes from the shell structure. The panels are subsequently coupled to shell structure. Devices for performing various steps of the methods are also provided.

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.

Abstract: An RFID tag system and method. An RFID tag is encapsulated within a protective material and formed as a ball. The RFID ball is then mixed with a material that is to be deposited on a particular work piece, such as a coating being deposited on a piece of sheet metal. The RFID ball can later be read when the work piece is in the production environment using a suitable RFID reader. In this manner, the RFID ball forms a permanent part of the work piece and is able to be interrogated at any occasion during the assembly of a product.

Abstract: Method and apparatus for detecting unacceptable misalignment of welding electrodes. An electrode-alignment station is positioned adjacent a welding station. A robot controls the movement of the electrodes, and occasionally moves the electrodes out of the welding station and into an electrode-alignment station. At the electrode-alignment station, the electrodes are closed on a fixture that transfers electrode-misalignment into movement of a plate that triggers an alarm if the misalignment is greater than a prescribed amount.

Abstract: Method and apparatus for detecting unacceptable misalignment of welding electrodes. An electrode-alignment station is positioned adjacent a welding station. A robot controls the movement of the electrodes, and occasionally moves the electrodes out of the welding station and into an electrode-alignment station. At the electrode-alignment station, the electrodes are closed on a fixture that transfers electrode-misalignment into movement of a plate that triggers an alarm if the misalignment is greater than a prescribed amount.

Abstract: A method for forming an electrical resistance weld between a metal tube and a metal sheet is disclosed. In the method, a plurality of generally circular protrusions having generally triangular cross sections is formed upon the sheet. Thereafter, electrodes are utilized to flex the tube, while an electrical current is generated for electric resistance welding the sheet to the tube.

Abstract: A method and apparatus for measuring the contact resistance at electrode-to-workpiece and workpiece-to-workpiece interfaces for spot welding simulations. A constant compressive load is applied through electrodes and workpieces to simulate a load applied during an actual resistance spot welding process. A discharging current circuit applies an initial high current of the order of 1.2 KA to electrodes and workpieces to break down contaminant films on surfaces of the workpieces. A relatively small constant current of about 2A is then applied to the electrodes and workpieces and the voltage across and the current flow through the electrodes and workpieces are measured. The contact resistance is determined from the measured voltage and current.