Abstract: To identify the sweet spot for criteria attributes (i.e., variables) within a complex system, a data source having objectively acceptable values or ranges of values for the criteria attributes for each variant of the system is generated. The identification system used to analyze the complex system to identify the sweet spot receives measurement values from a testing system that measures values of the criteria attributes from variants of the complex system and provides the measurement values to the identification system. The criteria attributes may be prioritized for determination of the sweet spot, including a selection of a value or range of values that are to be used for the most highly prioritized criteria attribute. The prioritized criteria attributes and objectively acceptable values can be used to filter the measurement values to identify the sweet spot for the variants of the complex system.

Abstract: To identify the sweet spot for criteria attributes (i.e., variables) within a complex system, a data source having objectively acceptable values or ranges of values for the criteria attributes for each variant of the system is generated. The identification system used to analyze the complex system to identify the sweet spot receives measurement values from a testing system that measures values of the criteria attributes from variants of the complex system and provides the measurement values to the identification system. The criteria attributes may be prioritized for determination of the sweet spot, including a selection of a value or range of values that are to be used for the most highly prioritized criteria attribute. The prioritized criteria attributes and objectively acceptable values can be used to filter the measurement values to identify the sweet spot for the variants of the complex system.

Abstract: To identify the sweet spot for criteria attributes (i.e., variables) within a complex system, a data source having objectively acceptable values or ranges of values for the criteria attributes for each variant of the system is generated. The identification system used to analyze the complex system to identify the sweet spot receives measurement values from a testing system that measures values of the criteria attributes from variants of the complex system and provides the measurement values to the identification system. The criteria attributes may be prioritized for determination of the sweet spot, including a selection of a value or range of values that are to be used for the most highly prioritized criteria attribute. The prioritized criteria attributes and objectively acceptable values can be used to filter the measurement values to identify the sweet spot for the variants of the complex system.

Abstract: To identify the sweet spot for criteria attributes (i.e., variables) within a complex system, a data source having objectively acceptable values or ranges of values for the criteria attributes for each variant of the system is generated. The identification system used to analyze the complex system to identify the sweet spot receives measurement values from a testing system that measures values of the criteria attributes from variants of the complex system and provides the measurement values to the identification system. The criteria attributes may be prioritized for determination of the sweet spot, including a selection of a value or range of values that are to be used for the most highly prioritized criteria attribute. The prioritized criteria attributes and objectively acceptable values can be used to filter the measurement values to identify the sweet spot for the variants of the complex system.

Abstract: The present disclosure is directed toward a dimensional automated linkage system for correlating a fixture with a workpiece. The system includes a fixture module repository, a barcode stamp, and a fixture-workpiece data controller. The fixture module repository stores a fixture record for a registered fixture module, where the fixture record includes a workpiece entry portion to link a fixture of the registered fixture module with a subject workpiece. The workpiece entry portion includes a fixture modification field to identify modifications made to the fixture for mounting the subject workpiece on the fixture. The barcode stamp is configured to include data to identify the fixture record for the registered fixture module. The fixture-workpiece data controller is communicably coupled to an external computing device and operable to populate the workpiece entry portion of the fixture record based on information acquired from the external computing device.

Abstract: A method is disclosed for verifying the alignment of a door with a door opening defined by a vehicle body sub-assembly. Sets of two-way sensors and a four-way sensors are used to locate feature, or hole, locations including a master hole location on the body/side. Other two-way sensors and four-way sensors are used to locate door hanging fixture pin locations on the doors before the doors are assembled to the body/side. After the doors are assembled to the body/side, two-way sensors and four-way sensors locate feature, or hole, locations on the installed doors and compare them to the previously measured master location.

Abstract: A method of assembling a door on a vehicle begins by identifying critical fit areas between the door seal and the door frame. Pressure indicator tape is adhered to the seal in critical fit areas and the door is closed against the seal to produce a marking on the pressure indicator tape. Intensity of the marking is visually compared to a reference pressure intensity scale to establish an observed pressure intensity level. The observed pressure intensity level may be recorded, correlated to a specific critical fit area and analyzed to make operational and design improvements to the door, door frame or seal.

Abstract: The present disclosure is directed toward a workpiece alignment system that includes a fixture configured to receive a workpiece, and multiple sensors disposed at different locations along the fixture. Each of the sensors is configured to detect a force applied to the sensor and to output a signal indicative of the force applied. Based on the signal, the system determined whether a workpiece is aligned on the fixture.

Abstract: The present disclosure is directed toward a dimensional automated linkage system for correlating a fixture with a workpiece. The system includes a fixture module repository, a barcode stamp, and a fixture-workpiece data controller. The fixture module repository stores a fixture record for a registered fixture module, where the fixture record includes a workpiece entry portion to link a fixture of the registered fixture module with a subject workpiece. The workpiece entry portion includes a fixture modification field to identify modifications made to the fixture for mounting the subject workpiece on the fixture. The barcode stamp is configured to include data to identify the fixture record for the registered fixture module. The fixture-workpiece data controller is communicably coupled to an external computing device and operable to populate the workpiece entry portion of the fixture record based on information acquired from the external computing device.

Abstract: A fluid application system includes a source of a fluid and a first pump for supplying the fluid under pressure to an applicator having a nozzle for dispensing the fluid. A fluid collection system collects reclaimed fluid dispensed from the applicator and a second pump provides the reclaimed fluid under pressure to a return fluid pipe. The return fluid pipe has a valve system that selectively directs the reclaimed fluid to either a reusable fluid container or the applicator. The valve system may selectively direct the reclaimed fluid from the return fluid pipe to an in-line reservoir and a third pump may be used to provide the reclaimed fluid under pressure from the in-line reservoir to the applicator.

Abstract: A fluid application system includes a source of a fluid and a first pump for supplying the fluid under pressure to an applicator having a nozzle for dispensing the fluid. A fluid collection system collects reclaimed fluid dispensed from the applicator and a second pump provides the reclaimed fluid under pressure to a return fluid pipe. The return fluid pipe has a valve system that selectively directs the reclaimed fluid to either a reusable fluid container or the applicator. The valve system may selectively direct the reclaimed fluid from the return fluid pipe to an in-line reservoir and a third pump may be used to provide the reclaimed fluid under pressure from the in-line reservoir to the applicator.

Abstract: A method is disclosed for verifying the alignment of a door with a door opening defined by a vehicle body sub-assembly. Sets of two-way sensors and a four-way sensors are used to locate feature, or hole, locations including a master hole location on the body/side. Other two-way sensors and four-way sensors are used to locate door hanging fixture pin locations on the doors before the doors are assembled to the body/side. After the doors are assembled to the body/side, two-way sensors and four-way sensors locate feature, or hole, locations on the installed doors and compare them to the previously measured master location.

Abstract: A method of assembling a door on a vehicle begins by identifying critical fit areas between the door seal and the door frame. Pressure indicator tape is adhered to the seal in critical fit areas and the door is closed against the seal to produce a marking on the pressure indicator tape. Intensity of the marking is visually compared to a reference pressure intensity scale to establish an observed pressure intensity level. The observed pressure intensity level may be recorded, correlated to a specific critical fit area and analyzed to make operational and design improvements to the door, door frame or seal.

Abstract: A method and system for measuring pressure in critical fit areas in the seal gap between a closure member and an opening defined by a vehicle. Critical contact pressure areas are identified and pressure profile data is measured across an area of surface contact in the seal gap with a thin strip-shaped electronic sensor. The electronic sensor includes a plurality of discreet pressure sensors arrayed across a sensor strip. The electronic sensor is inserted between the door and door opening while the door is “softly” closed against the seal. Pressure data may be analyzed and uploaded to a manufacturing database and control system.