Abstract: A method for inspecting an installed component includes receiving an identity and selected location of the component as an input signal via a handheld inspection device having a controller, digital camera, and display screen, and collecting a dynamic pixel image of the selected location in real-time using the digital camera. The method includes displaying the image in real time via the display screen, projecting virtual guidance lines onto the image corresponding to edges of the installed component, and identifying the component via the controller when the image is aligned with the projected acquisition lines. A predetermined area of the installed component is identified after identifying the installed component, a predetermined feature dimension is measured within the identified predetermined area, and an output signal is generated with a status indicative of whether the measured feature dimension falls within a calibrated range.

Abstract: A method for inspecting an installed component includes receiving an identity and selected location of the component as an input signal via a handheld inspection device having a controller, digital camera, and display screen, and collecting a dynamic pixel image of the selected location in real-time using the digital camera. The method includes displaying the image in real time via the display screen, projecting virtual guidance lines onto the image corresponding to edges of the installed component, and identifying the component via the controller when the image is aligned with the projected acquisition lines. A predetermined area of the installed component is identified after identifying the installed component, a predetermined feature dimension is measured within the identified predetermined area, and an output signal is generated with a status indicative of whether the measured feature dimension falls within a calibrated range.

Abstract: A number of variations may include a product including an installation device having a plurality of pillars which are constructed and arranged to accept a passenger airbag housing; wherein at least one sensor or switch is attached to the installation device which may physically engage at least one tab during the installation process and which may provide electronic feedback of the installation results. A number of variations may include a method including placing a passenger airbag assembly having at least one lock feature onto an instrument panel chute having at least one tab feature; placing the installation device having at least one sensor or switch attached to it onto the passenger airbag assembly; pressing down on the installation device to engage the at least one lock feature with the at least one tab feature; and wherein the at least one sensor or switch provides electronic feedback of the installation results.

Abstract: A movement device is configured for moving a payload. The movement device includes a first support, a second support, and an intermediate support. The intermediate support is operatively disposed between the first support and the second support. The intermediate support is jointed to the first support at two first joints and jointed to the second support at two second joints. The second support is configured for supporting the payload. The intermediate support is jointed to the second support at two second joints. The first joints are pivotable about a respective first axis of rotation such that the intermediate support moves relative to the first support. The second joints are pivotable about a respective first axis of rotation such that the second support moves relative to the intermediate support. Each of the first axes of rotation are in spaced and generally parallel relationship to one another.

Abstract: A human monitoring system includes a plurality of cameras and a visual processor. The plurality of cameras are disposed about a workspace area, where each camera is configured to capture a video feed that includes a plurality of image frames, and the plurality of image frames are time-synchronized between the respective cameras. The visual processor is configured to identify the presence of a human within the workspace area from the plurality of image frames, generate a motion track of the human within the workspace area, generate an activity log of one or more activities performed by the human throughout the motion track, and compare the motion track and activity log to an activity template that defines a plurality of required actions. The processor then provides an alert if one or more actions within the activity template are not performed within the workspace area.

Abstract: A number of variations may include a product including an installation device having a plurality of pillars which are constructed and arranged to accept a passenger airbag housing; wherein at least one sensor or switch is attached to the installation device which may physically engage at least one tab during the installation process and which may provide electronic feedback of the installation results. A number of variations may include a method including placing a passenger airbag assembly having at least one lock feature onto an instrument panel chute having at least one tab feature; placing the installation device having at least one sensor or switch attached to it onto the passenger airbag assembly; pressing down on the installation device to engage the at least one lock feature with the at least one tab feature; and wherein the at least one sensor or switch provides electronic feedback of the installation results.

Abstract: A fixture is configured for holding terminals of a battery in alignment. The fixture includes a first and a second side member. The first and second side members each include a plurality of first and second teeth, respectively. The second side member is movable relative to the first side member between an open position and a closed position. The second side member opposes the first side member such that a number of the first teeth oppose a corresponding number of the second teeth and a slit is defined between each of the adjacent teeth when the fixture is in the open position. Likewise, the second side member opposes the first side member such that the number of the first teeth are staggered from the corresponding number of the second teeth to reduce the slit in size when the fixture is in the closed position.

Abstract: A moving stop station includes a vehicle carrier configured to move a vehicle along an assembly line, an assembly platform disposed adjacent to the assembly line, and a synchronizer in communication with the vehicle carrier and the assembly platform. The synchronizer is configured to synchronize the motion of the assembly platform with the motion of the vehicle carrier as the vehicle carrier moves along a length of the assembly line, and includes a sensor, processor, and actuator. The sensor is configured to sense the position of the vehicle carrier and to generate a position signal corresponding to the sensed position. The processor is configured to receive the position signal and selectively provide a synchronization signal in response, and the actuator is configured to receive the synchronization signal and synchronize the motion of the vehicle carrier and the motion of the assembly platform in response.

Abstract: An assembly and method for automated installation of a flexible seal to a periphery of a component. The method may include positioning the periphery of the component adjacent to a seal feed assembly; employing a motor to move the seal toward the periphery of the component until a predetermined torque on the motor is reached; stopping movement of the motor when the predetermined torque is reached; moving the component relative to the seal feed assembly; and, as the component is moved relative to the seal feed assembly, automatically maintaining the predetermined torque in the motor by moving the seal toward the periphery of the component. The component may be a vehicle door to which a seal is installed.

Abstract: A press apparatus for assembly of a battery pack includes a tooling table having an aperture formed therein. The tooling table includes a plurality of index pawls disposed adjacent the aperture. The index pawls militate against the components passing upwardly through the aperture after the components have passed downwardly through the aperture. A first press is disposed on a first side of the tooling table and configured to advance the components downwardly through the aperture and past the index pawls on the tooling table. A second press is disposed on a second side of the tooling table. The second press is configured to retract a distance that the components are pressed downwardly through the aperture and maintain a substantially constant upward force on the components. A third press is disposed on the first side of the tooling table and configured to compress the battery pack to a desired size and load.

Abstract: A movement device is configured for moving a payload. The movement device includes a first support, a second support, and an intermediate support. The intermediate support is operatively disposed between the first support and the second support. The intermediate support is jointed to the first support at two first joints and jointed to the second support at two second joints. The second support is configured for supporting the payload. The intermediate support is jointed to the second support at two second joints. The first joints are pivotable about a respective first axis of rotation such that the intermediate support moves relative to the first support. The second joints are pivotable about a respective first axis of rotation such that the second support moves relative to the intermediate support. Each of the first axes of rotation are in spaced and generally parallel relationship to one another.

Abstract: A manufacturing method for battery pouches enables the subsequent welding together of a stack of battery terminals with an interconnect member to form a battery pack. According to the method, a plurality of pouches containing energy storage medium and having positive terminals and negative terminals extending therefrom are supported side by side in a pouch supporting fixture and lids are lowered to clamp the pouches against movement. The terminals are clamped against movement by clamping the terminals at the bases thereof. Then, the end portions of the terminals are bent by die mechanisms to provide an offset shape in each terminal by which when the pouches are stacked adjacent one another, the positive terminals will contact one another and the negative terminals will contact one another. The clamping and bending are performed in a way that prevents the flow of electrical current between the positive and negative terminals.

Abstract: A vehicle for transporting material along a defined path includes a chassis, a source of electric power mounted on the chassis, a traction system including a traction motor connected to the power source for driving wheels supporting the chassis, a steering system including steering motor connected to the power source for adjusting an angular position of a steerable wheel supporting the chassis, and a controller for adjusting the vehicle's speed and direction by controlling operation of the traction motor and steering motor in response to information regarding the vehicle's location and travel direction relative to the path.

Abstract: A moving stop station includes a vehicle carrier configured to move a vehicle along an assembly line, an assembly platform disposed adjacent to the assembly line, and a synchronizer in communication with the vehicle carrier and the assembly platform. The synchronizer is configured to synchronize the motion of the assembly platform with the motion of the vehicle carrier as the vehicle carrier moves along a length of the assembly line, and includes a sensor, processor, and actuator. The sensor is configured to sense the position of the vehicle carrier and to generate a position signal corresponding to the sensed position. The processor is configured to receive the position signal and selectively provide a synchronization signal in response, and the actuator is configured to receive the synchronization signal and synchronize the motion of the vehicle carrier and the motion of the assembly platform in response.

Abstract: An assembly and method for automated installation of a flexible seal to a periphery of a component. The method may include positioning the periphery of the component adjacent to a seal feed assembly; employing a motor to move the seal toward the periphery of the component until a predetermined torque on the motor is reached; stopping movement of the motor when the predetermined torque is reached; moving the component relative to the seal feed assembly; and, as the component is moved relative to the seal feed assembly, automatically maintaining the predetermined torque in the motor by moving the seal toward the periphery of the component. The component may be a vehicle door to which a seal is installed.

Abstract: An alignment tool determines the parallelism between the anvil face of an anvil of an ultrasonic welder and the horn faces of a replacement horn mounted on the welder by a rotary mount. The tool includes a tool base having a face plate contacting with the anvil face and a clamp for clamping the tool base on the anvil. A plate member is mounted on the tool base for swiveling movement and contacts the horn faces. Springs urge the plate member into contact with the horn faces while the replacement horn is rotated relative to the anvil. Transducers sense the relative positions between the face plate and the plate member so that the repairman can determine that the replacement horn has been rotated to the desired position in which the horn face has become parallel with the anvil face. Then the replacement horn can then be tightened against further rotation.

Abstract: An actuation system includes a bridge crane, a trolley, and an end effector and is configured for moving a payload. A first actuator is operatively connected to the bridge crane. The bridge crane is configured for moving along an X axis in response to the first actuator being actuated. The trolley extends from the bridge crane. A second actuator is operatively connected to the trolley. The trolley is configured for moving along a Y axis in response to the second actuator being actuated. The end effector extends from the trolley and is configured for supporting a payload. A third actuator is operatively connected to the end effector. The end effector is configured for rotating about the Z axis in response to the third actuator being actuated to rotate the end effector. Each actuator is disposed in spaced relationship to the bridge crane, the trolley, and the end effector.

Abstract: A clamp is configured for compressing a section of a battery module. The clamp includes a body, an arm, a first jaw, and a second jaw. The first jaw is operatively connected to the body. The arm is operatively connected to the body. The second jaw is operatively connected to the arm. Each jaw is con figured to engage opposing ends of the battery module. The arm is slidably attached to the body to allow linear movement of the arm relative to the body along an axis. The second jaw moves with the arm a clamping distance between an extended position, for releasing the section of the battery module, and a compressed position, for holding the section of the battery module in compression between the jaws.

Abstract: A cart for moving loads includes a frame supported on wheels, a source of electric power supported on the frame, a drive system including a traction motor connected to the power source for driving a wheel secured to the frame and contacting ground, and a controller for adjusting a rotary direction of the drive wheel in response to selected states of an input to the controller.

Abstract: An alignment tool determines the parallelism between the anvil face of an anvil of an ultrasonic welder and the horn faces of a replacement horn mounted on the welder by a rotary mount. The tool includes a tool base having a face plate contacting with the anvil face and a clamp for clamping the tool base on the anvil. A plate member is mounted on the tool base for swiveling movement and contacts the horn faces. Springs urge the plate member into contact with the horn faces while the replacement horn is rotated relative to the anvil. Transducers sense the relative positions between the face plate and the plate member so that the repairman can determine that the replacement horn has been rotated to the desired position in which the horn face has become parallel with the anvil face. Then the replacement horn can then be tightened against further rotation.