Abstract: A reconfigurable end-effector attachable to a robotic arm, includes a master boom, a first branch assembly and a second branch assembly, a dual articulation mechanism. The dual articulation mechanism includes a first clutch attached to the first branch assembly and is configured to articulate the first branch assembly relative to the second branch assembly. The dual articulation mechanism further includes a second clutch attached to the master boom, the second branch assembly and the first clutch and is configured to simultaneously articulate the first and second branch assemblies relative to the master boom. The first and second branch assemblies each have limbs connected to branches supporting a plurality of tool modules. Each tool module includes an end element configurable to interact with a workpiece.

Abstract: The present invention provides a flexible support assembly for supporting and/or locating a fixture on a tooling plate. The support assembly includes a stanchion with a bore, and a threaded portion on an inner-diameter surface thereof. A base plate is attached to, and configured to repositionably fix the stanchion to the tooling plate. A cylindrical sleeve with a threaded portion on an outer-diameter surface thereof is threadably engaged with the stanchion, whereby the sleeve is operable to telescope with respect to the stanchion between a first, lowest position and a second, highest position. A nut is threadably engaged with the sleeve to lock the sleeve at any predetermined position between the first and second positions. A locator pin is releasably engaged with the sleeve at a first end thereof. The locator pin has a protrusion projecting outward from a second opposing end thereof for engaging a pinhole in the fixture.

Abstract: A safety monitoring system for a workspace area. The workspace area related to a region having automated moveable equipment. A plurality of vision-based imaging devices capturing time-synchronized image data of the workspace area. Each vision-based imaging device repeatedly capturing a time synchronized image of the workspace area from a respective viewpoint that is substantially different from the other respective vision-based imaging devices. A visual processing unit for analyzing the time-synchronized image data. The visual processing unit processes the captured image data for identifying a human from a non-human object within the workspace area. The visual processing unit further determining potential interactions between a human and the automated moveable equipment.

Abstract: An error detection vision system that determines whether a proper part has been selected from a presentation device during an assembly process. In one embodiment, the presentation device is a rack including a plurality of bins, where the bins hold a plurality of different parts. The vision system includes one or more projecting devices that project a light beam towards the presentation device and a detector, such as a camera, receiving reflections back from a worker as he selects parts from the presentation device. The error detection vision system can employ various detection processes, such as a stereo pair of video cameras, vision using structured-light triangulation and infrared time-of-flight distance measurements.

Abstract: A method is provided for monitoring and controlling the process consistency of an arc welding process. The weld voltage signal is monitored and analyzed to determine the occurrence of the detachment of a weld droplet. The weld droplet detachment is determined via statistical techniques as having occurred at a normal interval following a prior detachment indicating consistent weld process or as a sporadic detachment having occurred at an irregular interval with respect to the prior detachment and indicating inconsistent weld process. The weld process is adjusted by controlling the weld process variables to maximize the predominance of droplet detachment at normal intervals and minimize the occurrence of the sporadic detachments.

Abstract: An active material-based device for and related method of clamping and releasing objects. Broadly, the device includes an elongated piece of active material, such as a wire, having an actuation temperature and arranged to form a sleeve defining a volume of space. When the active material reaches the actuation temperature the material changes, which causes one or more dimensions of the volume of space to change. An object located within the sleeve experiences either a clamping or releasing force resulting from the change in the volume of space.

Abstract: An end-of-arm tool having a workpiece interface tool is attachable to an articulable robotic arm. The end-of-arm tool can be configured by engaging an adjustable modular unit including a swing arm, a cylinder, and a workpiece interface tool to a rail element of the end-of-arm tool. The adjustable modular unit machine-slides in the rail element to a preferred x-axis position, machine-pivots to a preferred angular orientation, and machine-extends along a longitudinal axis of the cylinder to a preferred z-axis position, and machine-rotates to a preferred rotational angle about the z-axis.

Abstract: A system is configured to determine the performance of a braking system for a joint of a robot. The braking system is configured to apply a brake to the joint and a servo system is configured to apply a torque to the joint. The system measures performance data at the joint, identifies a performance parameter, and defines performance regions and limits that are used to evaluate the performance parameter.

Abstract: A configurable end-of-arm tool attachable to an articulable robotic arm is described. The end-of-arm tool comprises a rail element, a machine-adjustable swing arm, a machine-adjustable extendable shaft attached to the swing arm. A machine-adjustable rotator set is attached to the extendable shaft, and a workpiece interface tool is attached to the extendable shaft. The swing arm, the extendable shaft, and the rotator set are machine-adjustable to place the workpiece interface tool at a predetermined position.

Abstract: A tool module associated with an end-effector for a robot arm that includes both linear and rotational locking mechanisms providing movement in five degrees of freedom. The tool module includes an integrated locking assembly that includes a linear locking mechanism and a rotary locking mechanism that are simultaneously locked and unlocked. The linear locking mechanism locks to a rod and the rotary locking mechanism locks and unlocks a shaft that is rigidly coupled to a swing arm. An opposite end of the swing arm includes another linear locking mechanism that locks and unlocks a shaft supporting a vacuum cup at an opposite end. The vacuum cup is mounted to a ball joint on the shaft that allows the vacuum cup to pivot. By locking and unlocking the locking mechanisms of the tool module, the end-effector can be readily configured to grasp and hold various parts of different dimensions and shapes.

Abstract: The cable lift system provides assistance to movement of a flexibly suspended payload actuated by operator input into one or more sensing devices attached to the payload. The sensing device is configured to collect information about the typical push-pull and lift-lower motions of an operator moving the payload horizontally and/or vertically, such that the operator's input to the sensor is intuitive and is provided in a manner which is substantially transparent to the operator. The assist mechanisms included in the system are actuated by a controller processing signals received from the one or more sensing devices on the payload. Movement assistance is provided such that the manual effort required by the operator to overcome the inertia of the payload in a starting or stopping event is substantially relieved, thus minimizing the ergonomic impact of the starting and stopping events on the operator.

Abstract: A robotic system includes a robot adapted for moving a payload in proportional response to an input force from an operator, sensors adapted for measuring a predetermined set of operator input values, including the input force, and a controller. The controller determines a changing stiffness value of the operator using set of operator input values, and automatically adjusts a level of control sensitivity over the robot using the stiffness value. The input values include the input force, a muscle activation level of the operator, and a position of the operator. A method of controlling the robot includes measuring the operator input values using the plurality of sensors, processing the input values using the controller to thereby calculate the stiffness value, and automatically adjusting the level of control sensitivity over the robot using the stiffness value. A specific operator may be identified, with control sensitivity being adjusted based on the identity.

Abstract: A battery module includes a plurality of electrochemical battery cells positioned adjacent one another and each having a positive cell tab and a negative cell tab. The positive cell tab of a first of the electrochemical battery cells is overlappingly joined to the negative cell tab of a second of the plurality of electrochemical battery cells. Each of the positive cell tabs and the negative cell tabs is not joined to a conductive interconnecting member. At least one of the positive cell tabs or the negative cell tabs defines a flexure configured for reducing stress applied to the electrochemical battery cells during overlappingly joining the positive cell tabs and the negative cell tabs.

Abstract: A safety monitoring system for a workspace area. The workspace area related to a region having automated moveable equipment. A plurality of vision-based imaging devices capturing time-synchronized image data of the workspace area. Each vision-based imaging device repeatedly capturing a time synchronized image of the workspace area from a respective viewpoint that is substantially different from the other respective vision-based imaging devices. A visual processing unit for analyzing the time-synchronized image data. The visual processing unit processes the captured image data for identifying a human from a non-human object within the workspace area. The visual processing unit further determining potential interactions between a human and the automated moveable equipment.

Abstract: A method is provided for precisely positioning and joining first and second sheet panels. A first hole is extruded in the first panel with an annular upstanding wall surrounding the first hole. The first hole has a diameter to fit closely over the locating pin of a support. A second hole is formed in the second panel and has a diameter to fit closely over the annular upstanding wall of the first panel. A bond is created between the first and second panels adjacent to the annular upstanding wall, so that the annular upstanding wall protects the locating pin from being fouled by the bonding material. The bond may be either an adhesive bond or an electric resistance weld or both an adhesive bond and an electric resistance weld and the annular upstanding wall acts as a dam to protect the locating pin from the adhesive or weld splatter.

Abstract: Method and apparatus is provided for monitoring the installation of a blind rivet to attach together top and bottom members. The blind rivet installation tool includes a housing having an anvil seated on the rivet head. A collet is reciprocable within the tool housing and carries jaws for gripping the mandrel of the blind rivet. Retraction of the jaws by the collet displaces the jaws and the mandrel axially and causes the mandrel head to axially collapse and radially expand the hollow shank of the blind rivet into engagement with the bottom member so that the rivet attaches the top member and the bottom member. A cut off tool is actuated by an actuator to cut off the mandrel flush with the rivet head. Transducers and a process controller monitor the installation process and actuate the cut off blade upon determining that the blind rivet is properly installed.

Abstract: A method of minimizing mechanical resonance in an assembly during formation of a vibration-welded joint therein includes positioning work pieces such that they are directly adjacent to each other, and generating a set of control signals that cause one or more sonotrode weld heads to vibrate. A waveform characteristic of a mechanical oscillation of the sonotrode(s) and weld head(s) is varied to minimize the mechanical resonance occurring in the assembly, such as a multi-cell battery for a vehicle. An apparatus for forming the welded joint includes at least one sonotrode having a weld head or heads formed integrally therewith, and a weld controller. The controller is connected to a converter, sonotrode(s), and weld head(s), with the mechanical oscillation occurring in the sonotrode(s) and weld head(s). Variation of the control signals during formation of the welded joint varies a waveform characteristic of the mechanical oscillation, thus minimizing the mechanical resonance.

Abstract: A method of minimizing mechanical resonance in an assembly during formation of a vibration-welded joint therein includes positioning work pieces such that they are directly adjacent to each other, and generating a set of control signals that cause one or more sonotrode weld heads to vibrate. A waveform characteristic of a mechanical oscillation of the sonotrode(s) and weld head(s) is varied to minimize the mechanical resonance occurring in the assembly, such as a multi-cell battery for a vehicle. An apparatus for forming the welded joint includes at least one sonotrode having a weld head or heads formed integrally therewith, and a weld controller. The controller is connected to a converter, sonotrode(s), and weld head(s), with the mechanical oscillation occurring in the sonotrode(s) and weld head(s). Variation of the control signals during formation of the welded joint varies a waveform characteristic of the mechanical oscillation, thus minimizing the mechanical resonance.

Abstract: A process generally includes contacting a surface of at least one workpiece with a reconfigurable pad of a fixture device, wherein the reconfigurable pad comprises a shape memory material configured to conform to the surface of the at least one workpiece, and fixturing the contacted workpiece.

Abstract: A method, system, and computer program product for automated root cause identification of a failure of a logic controller have been provided. The method includes receiving logic controller failure information, receiving a logic model of logic code for the logic controller, and mapping the logic controller failure information to the logic model to identify a logic failure model state. The method further includes determining a potential trigger of the failure of the logic controller as a root cause via tracing through at least one path in the logic model to reach the logic failure model state. The method also includes identifying the root cause in the logic code via mapping the root cause from the logic model to the logic code, and outputting the logic code with the identified root cause of the failure of the logic controller.