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: The end-effector includes an articulating frame mounted on an indexable boom. Tool modules mount on the end-effector and connect to a workpiece. Each tool module includes a flexible dress package including a cable carrier. A channel rail is supported by the end-effector frame and guides the cable carrier. A setup tool and associated process can reconfigure the positions of the tool modules and the frame and boom of the end-effector.

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: A system, method and apparatus for resource reallocation based on ambient condition data is disclosed herein. The system includes a planning module (102) for configuring plan data to include a primary sequence and an auxiliary sequence, a rule table (116) for storing the auxiliary sequence, an ambient condition receiver (124) for receiving the ambient condition data, and a routing processor (126) for accessing the rule table (116) to allocate an auxiliary sequence in place of a primary sequence in the event that particular ambient data is received.

Abstract: A fixture device generally includes a base member, a reconfigurable pad disposed on the base member, wherein the reconfigurable pad comprises a shape memory material configured to selectively conform to a surface contour of a workpiece, and an activation device in operative communication with the shape memory material.

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: 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 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: 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.

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 system, method, and apparatus are provided for maintenance opportunity planning in a production line having a plurality of machines and buffers between machines on the production line, with the buffers processing production units between at least two of the machines. The system, method, and apparatus advantageously indicates maximum allowed downtime for a machine, through monitoring the status of the buffers to determine whether the flow of units through the buffers is favorable, monitoring the status of the plurality of machines, and determining which of the plurality of machines may be shut down for a particular period of time while substantially maintaining the favorable flow of units through the buffers. In this way, the inventive system and method saves time and resources by reducing production line downtime and unscheduled overtime.

Abstract: A reconfigurable clamp for a flexible manufacturing system comprises a body portion, a plurality of pins slidably engaged within sleeves formed in the body portion, a compression spring attached to each shaft of the plurality of pins, a reservoir comprising a magnetorheological fluid in operative communication with the plurality of pins, and an electromagnet in operative communication with the magnetorheological fluid, wherein the electromagnet selectively increases a yield stress property of the magnetorheological fluid; and a matching pressure foot.

Abstract: A method of improving weld quality between aluminum members by slowing the rate of solidification of a molten weld trough into solidified material. Upper and lower aluminum members are positioned together in contact between facing surfaces thereof to expose a first outer surface of the upper aluminum member to laser irradiation. A welding laser beam is moved in a path over the first outer surface, wherein the welding laser beam has an energy and width to progressively melt a trough of molten metal to a depth through the upper aluminum member and into the lower aluminum member. The molten metal in the trough has a void filled with gas, and the molten metal re-solidifies into re-solidified metal after the passage of the welding laser beam. An area in and around the trough is heated to slow the rate of solidification of the molten metal into the re-solidified metal, thereby preventing entrainment of the gas within the re-solidified metal.