Abstract: A set-up stand is provided including a counterbalance mechanism for use in reconfiguring an end-effector with an articulating portion rotated by a bi-directional rotary locking device, for example, a clutch. A counterbalance mechanism is provided including a holding member which is attached to a preloaded member and connected to an articulating portion of the end-effector during reconfiguration of the end-effector. The preloaded member provides a tension load to counterbalance the gravity moment load of the articulating portion when the articulated portion is rotated in the same direction as the output shaft of the bi-direction rotary locking device, to prevent overhauling, chattering or binding stops during rotation and reconfiguration. A method is provided to utilize the counterbalance mechanism as described.

Abstract: A robotic system includes a robotic arm and an end-effector assembly movably coupled to the robotic arm. The end-effector assembly includes a main boom, a frame rail coupled to the main boom, and a plurality of tool branches movably coupled to the frame rail. Each tool branch includes a branch rail movably coupled to the frame rail, a lock coupling the branch rail to the frame rail, and a protrusion coupled to the first lock. The robotic system also includes a configuration tool movably coupled to the robotic arm. The configuration tool includes including a tool body, a gripper coupled to the tool body, and a driver bit extending from the tool body.

Abstract: A method includes the following steps: actuating a robotic arm to perform an action at a start position; moving the robotic arm from the start position toward a first position; determining from a vision process method if a first part from the first position will be ready to be subjected to a first action by the robotic arm once the robotic arm reaches the first position; commencing the execution of the visual processing method for determining the position deviation of the second part from the second position and the readiness of the second part to be subjected to a second action by the robotic arm once the robotic arm reaches the second position; and performing a first action on the first part using the robotic arm with the position deviation of the first part from the first position predetermined by the vision process method.

Abstract: A reconfigurable interface assembly includes, but is not limited to, a first sub-assembly that is adapted for attachment to a work-piece supporter. The first sub-assembly includes a first brake. The reconfigurable interface assembly further includes a second sub-assembly attached to the first sub-assembly. The second sub-assembly is adapted for attachment to a work-piece manipulator. The second sub-assembly includes a second brake. The first sub-assembly is configured to move the second sub-assembly in a first direction with respect to the first sub-assembly and the first brake is configured to inhibit movement of the second sub-assembly in the first direction with respect to the first sub-assembly. The second sub-assembly is configured to move the first sub-assembly in a second direction with respect to the second sub-assembly and the second brake is configured to inhibit movement of the first sub-assembly in the second direction with respect to the first sub-assembly.

Abstract: A method for generating a candidate assembly system layout for an assembled product includes inputting a bill of materials including a list of components for the assembled product and determining a plurality of assembly patterns for the assembled product including a plurality of intermediate assemblies and sub-assemblies. A basic task layout is determined that includes assembly tasks for assembling the assembled product based upon a selected one of the assembly patterns. A whole task layout is determined based upon the basic task layout for the selected assembly pattern. Candidate assembly machines are selected for the whole task layout, and zoning constraints are identified for the candidate assembly machines related to assembly tasks. A candidate assembly system layout is generated based upon the whole task layout, the selected candidate assembly machines and the zoning constraints, from which a simulation model of a candidate assembly system is generated.

Abstract: A robotic system includes a robotic arm and an end-effector assembly movably coupled to the robotic arm. The end-effector assembly includes a main boom, a frame rail coupled to the main boom, and a plurality of tool branches movably coupled to the frame rail. Each tool branch includes a branch rail movably coupled to the frame rail, a lock coupling the branch rail to the frame rail, and a protrusion coupled to the first lock. The robotic system also includes a configuration tool movably coupled to the robotic arm. The configuration tool includes including a tool body, a gripper coupled to the tool body, and a driver bit extending from the tool body.

Abstract: A reconfigurable autonomous workstation includes a multi-faced superstructure including a horizontally-arranged frame section supported on a plurality of posts. The posts form a plurality of vertical faces arranged between adjacent pairs of the posts, the faces including first and second faces and a power distribution and position reference face. A controllable robotic arm suspends from the rectangular frame section, and a work table fixedly couples to the power distribution and position reference face. A plurality of conveyor tables are fixedly coupled to the work table including a first conveyor table through the first face and a second conveyor table through the second face. A vision system monitors the work table and each of the conveyor tables. A programmable controller monitors signal inputs from the vision system to identify and determine orientation of the component on the first conveyor table and control the robotic arm to execute an assembly task.

Abstract: A robotic system includes a robot, an end-effector assembly disposed at a distal end of a main boom, rotatable parallel frame rails, and tool support branches. Tool modules are connected to a tool support branch and rotatable/translatable with respect to a respective branch axis. A configuration tool has a control block engaged by a wrist of the robot and a work tool. A controller commands the robot to automatically configure the end-effector assembly by adjusting the frame rails and/or tool support branches or tool modules using the work tool, doing so in response to an identified work task. Engagement of the wrist with the tool changer is commanded and the identified work task is executed using the end-effector assembly. A configuration stand may automatically flip the end-effector assembly to a configuration location, command engagement of the wrist with the tool changer, and configure the end-effector assembly.

Abstract: A system and method for stacking battery cells or related assembled components. Generally planar, rectangular (prismatic-shaped) battery cells are moved from an as-received generally vertical stacking orientation to a generally horizontal stacking orientation without the need for robotic pick-and-place equipment. The system includes numerous conveyor belts that work in cooperation with one another to deliver, rotate and stack the cells or their affiliated assemblies. The belts are outfitted with components to facilitate the cell transport and rotation. The coordinated movement between the belts and the components promote the orderly transport and rotation of the cells from a substantially vertical stacking orientation into a substantially horizontal stacking orientation.

Abstract: A releasable adhesive system for joining a first surface to a second surface. The system includes a primary material having a first portion including at least one first-portion molecule configured to be positioned parallel with at least one first-surface molecule of the first surface, and a second portion, opposite the first portion, including at least one second-portion molecule configured to be positioned parallel with at least second surfaced one molecule of the second surface. The first surface molecule, positioned parallel with the first-surface molecule, is configured to maintain bonds between the first portion and the first surface up to one or more pre-determined force scenarios, such as pre-determined shear, pull, and peel forces being exerted on the first surface. The second portion can function similarly with respect to the second surface. A method is also provided for joining the first surface to the second surface using such releasable adhesive.

Abstract: A releasable adhesive system, for securing a suction device to an attaching surface. The releasable adhesive comprises a primary material having a first portion including at least one first-portion molecule that is configured to be positioned parallel with at least one molecule of the attaching surface, and a second portion, opposite the first portion, that is configured to permanently attach to an interior surface of the suction device. The first-portion molecule positioned parallel with the molecule of the attaching surface is configured to maintain a bond between the first portion and the attaching surface up to one or more pre-determined forces on the attaching surface, such as a pre-determined shear force, pull force, and peel force. Also provided is method for using the suction device on the attaching surface, wherein the suction device contains the releasable adhesive.

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: A reconfigurable end-effector assembly includes a master boom, a limb, and branches. The branches extend radially outward from the limb. Tandem branch joint assemblies connect the branches to the limb, and include a first and a second branch joint each having a cam lock. Tool modules mounted to the branches are translatable and rotatable with respect to the branches. The joint assemblies rotate and slide with respect to the longitudinal axis of the limb only when the cam lock is released. A configuration tool has an actuator and fingers. The branch joints define openings that are engaged via the fingers. The tool includes a latch which engages the cam lock, and clamps and unclamps the cam lock. A flexible dress package is mountable to the limb and configured to route lengths of conduit to each of the tool modules.

Abstract: A method includes the following steps: actuating a robotic arm to perform an action at a start position; moving the robotic arm from the start position toward a first position; determining from a vision process method if a first part from the first position will be ready to be subjected to a first action by the robotic arm once the robotic arm reaches the first position; commencing the execution of the visual processing method for determining the position deviation of the second part from the second position and the readiness of the second part to be subjected to a second action by the robotic arm once the robotic arm reaches the second position; and performing a first action on the first part using the robotic arm with the position deviation of the first part from the first position predetermined by the vision process method.

Abstract: A system and method for stacking battery cells or related assembled components. Generally planar, rectangular (prismatic-shaped) battery cells are moved from an as-received generally vertical stacking orientation to a generally horizontal stacking orientation without the need for robotic pick-and-place equipment. The system includes numerous conveyor belts that work in cooperation with one another to deliver, rotate and stack the cells or their affiliated assemblies. The belts are outfitted with components to facilitate the cell transport and rotation. The coordinated movement between the belts and the components promote the orderly transport and rotation of the cells from a substantially vertical stacking orientation into a substantially horizontal stacking orientation.

Abstract: A reconfigurable end-effector assembly includes a master boom, a limb, and branches. The branches extend radially outward from the limb. Tandem branch joint assemblies connect the branches to the limb, and include a first and a second branch joint each having a cam lock. Tool modules mounted to the branches are translatable and rotatable with respect to the branches. The joint assemblies rotate and slide with respect to the longitudinal axis of the limb only when the cam lock is released. A configuration tool has an actuator and fingers. The branch joints define openings that are engaged via the fingers. The tool includes a latch which engages the cam lock, and clamps and unclamps the cam lock. A flexible dress package is mountable to the limb and configured to route lengths of conduit to each of the tool modules.

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: A weld-free, frameless battery design is provided. The design reduces the number of parts and the weight of the battery pack, simplifies the assembly operation, and keeps the battery pack reparable and remanufacturable with minimal effort and cost. The battery pack includes a stack of battery cells and cooling fins, and a removable restraint is placed around the stack. The positive and negative tabs of the battery cells comprise a pair of sub-tabs which are bent over the faces of the cell. One type of cell can have an extended portion on one of the positive and one the negative sub-tabs which are on opposite faces of the cell. The sub-tabs are used to make the necessary series and parallel connections.

Abstract: A method and apparatus for assembling a fuel cell stack is disclosed, wherein the apparatus includes a plurality of dunnage cassettes adapted to cooperate with a plurality of containers, a fixture, and an assembly device to simultaneously assemble a plurality of membrane electrode assemblies together with a plurality of bipolar plates.

Abstract: An integrated locking device that includes both a linear locking mechanism and a rotary locking mechanism. The locking device includes a housing where the linear locking mechanism and the rotary locking mechanism are mounted to different sides of the housing so as to reduce the height of the device.