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: 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 forming over part system including a first roll of a first paint film, a second roll of a second paint film, a film adhering device, and a film positioning device. The film adhering device receives the first paint film. The film adhering device is configured to adhere the first paint film to a component of a vehicle. The film positioning device is configured to hold the first and second rolls and based on actuation of an actuator, position the second roll of the second paint film to the film adhering device while the film adhering device is applying the first paint film to the component.

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 partially assembled vehicle that autonomously completes its own assembly, including a chassis, wheels that are rotationally coupled to the chassis, a drive system mounted on the chassis and in operational communication with the wheels, a navigation system, a central platform controller, and a position determining system. Added thereto is a safety sensor guidance system and a controller circuit programmed to begin a temporary takeover of the central platform controller, responsive to an external fleet control. The temporary takeover including the steps of identifying a plurality of assembly stations that the partially assembled vehicle must visit to complete its own assembly; constructing a sequence in which to visit each of the plurality of assembly stations; and commanding the drive system to propel and steer the partially assembled vehicle through the sequence of the plurality of assembly stations, responsive to sensor input from the safety sensor guidance system.

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: A system includes a platform to support a vehicle on a first side of the platform and a passive motion device arranged on a second side of the platform, opposite the first side, to move upon actuation. A mechanical actuator actuates the passive motion device based on movement of one or more wheels of the vehicle to change a position of the vehicle. The position of the vehicle relative to the platform is unchanged and the passive motion device is actuated by only the movement of the one or more wheels of the vehicle to change the position of the vehicle.

Abstract: A system includes a platform to support a vehicle on a first side of the platform and a passive motion device arranged on a second side of the platform, opposite the first side, to move upon actuation. A mechanical actuator actuates the passive motion device based on movement of one or more wheels of the vehicle to change a position of the vehicle. The position of the vehicle relative to the platform is unchanged and the passive motion device is actuated by only the movement of the one or more wheels of the vehicle to change the position of the vehicle.

Abstract: A partially assembled vehicle that autonomously completes its own assembly, including a chassis, wheels that are rotationally coupled to the chassis, a drive system mounted on the chassis and in operational communication with the wheels, a navigation system, a central platform controller, and a position determining system. Added thereto is a safety sensor guidance system and a controller circuit programmed to begin a temporary takeover of the central platform controller, responsive to an external fleet control. The temporary takeover including the steps of identifying a plurality of assembly stations that the partially assembled vehicle must visit to complete its own assembly; constructing a sequence in which to visit each of the plurality of assembly stations; and commanding the drive system to propel and steer the partially assembled vehicle through the sequence of the plurality of assembly stations, responsive to sensor input from the safety sensor guidance system.

Abstract: An autonomous vehicle guidance system enables a partially assembled battery-electric vehicle (BEV) to be guided through an assembly process with the temporary addition of a sensor skid. The partially assembled BEV includes a vehicle body, a vehicle controller coupled to the vehicle body, a battery electrically coupled to the vehicle controller, a sensor skid configured to be coupled under the vehicle body of the BEV. The sensor skid is configured to guide the BEV through an assembly process. The sensor skid includes a skid body configured to be coupled under the vehicle body of the BEV and a plurality of sensors coupled to the skid body. The sensor skid includes a skid controller in communication with the sensors and the vehicle controller. The skid controller is coupled to the sensor skid.

Abstract: An autonomous vehicle guidance system enables a partially assembled battery-electric vehicle (BEV) to be guided through an assembly process with the temporary addition of a sensor skid. The partially assembled BEV includes a vehicle body, a vehicle controller coupled to the vehicle body, a battery electrically coupled to the vehicle controller, a sensor skid configured to be coupled under the vehicle body of the BEV. The sensor skid is configured to guide the BEV through an assembly process. The sensor skid includes a skid body configured to be coupled under the vehicle body of the BEV and a plurality of sensors coupled to the skid body. The sensor skid includes a skid controller in communication with the sensors and the vehicle controller. The skid controller is coupled to the sensor skid.

Abstract: A reconfigurable fixture and method for holding a sheet metal part for processing, assembly, or inspection is provided. The reconfigurable fixture includes a holding container made of a flexible material, and holding granules at least partially filling the holding container. The holding container and the holding granules cooperate to conform to the sheet metal part when the sheet metal part is placed on the holding container.

Abstract: A system for assembling a first component and a second component comprises a support operatively supporting the first component without any fixtures, a vision system configured to view the supported first component and the second component and determine the locations thereof, a robotic system configured to move and position the second component relative to the first component, and a controller operatively connected to the vision system and to the robotic system and operable to control the robotic system to position the second component relative to the first component based on the locations determined by the vision system. Various methods of assembling the first component and the second component are provided to create a process joint prior to creation of a structural joint in a subsequent assembly operation.

Abstract: Provided is a system and a method for identifying inefficiency of energy utilization in a facility by using actual past consumption data. The method uses the past energy usage data, weather information, production information, and variables estimated using Stochastic Frontier equation to calculate energy inefficiency for a production facility.

Abstract: Methods of forecasting and modulating energy consumption at a production facility are provided. The amounts of energy consumed during production and non-production times are used to obtain highly accurate hourly energy use rates for different energy use activities which are used to estimate the amount of energy that will be consumed during a subsequent time period. The forecasting and modulating methods provide a more tailored estimate of energy usage that prevents the unnecessary expense of using on-demand energy without the benefit of a pre-purchased or pre-reserved discount. The forecasting and modulating methods also help prevent overestimation of the amount of energy used.

Abstract: Methods of forecasting and modulating energy consumption at a production facility are provided. The amounts of energy consumed during production and non-production times are used to obtain highly accurate hourly energy use rates for different energy use activities which are used to estimate the amount of energy that will be consumed during a subsequent time period. The forecasting and modulating methods provide a more tailored estimate of energy usage that prevents the unnecessary expense of using on-demand energy without the benefit of a pre-purchased or pre-reserved discount. The forecasting and modulating methods also help prevent overestimation of the amount of energy used.