Abstract: The subject methods and apparatus allow the buyer of an automobile to configure and design a personalized interior space prior to purchasing the automobile. The buyer selects modular interior components from a library of choices provided by the manufacturer, and designs his/her custom automobile by using an interactive design domain system that allows realistic visualization of the developing interior with the incorporation of the buyer's anthropometric information. The method and apparatus guarantee conformance to applicable safety, geometric and functional constraints through the application of a rules-database. The produced automobile will fit exactly the customer's taste, physical dimensions, and personal requirements. The apparatus includes a computer that hosts a decision-support and feedback system, a database of safety, geometric and functional rules, and a database of interior components.

Abstract: A reconfigurable illumination system for illuminating an object, and associated method. The illumination system comprises a cylindrical diffuser having a longitudinal aperture, a linescan camera positioned for having a direct line of sight to the object through the aperture of the diffuser, a base, and an illuminator supported on the base and positioned between the diffuser and the object, wherein the illuminator is selectively reconfigurable in a plurality of configurations, each configuration corresponding to a manufacturing process that requires visual inspection of the object.

Abstract: A machine vision inspection system. The system includes a plurality of cells adjustably interconnected, and a plurality of vision elements. Each vision element can be adjustably supported within one of the cells. The cells and the vision elements can be selectively configured to define a vision arrangement capable of high-resolution inspection of a part.

Abstract: A reconfigurable illumination system for illuminating an object, and associated method. The illumination system comprises a cylindrical diffuser having a longitudinal aperture, a linescan camera positioned for having a direct line of sight to the object through the aperture of the diffuser, a base, and an illuminator supported on the base and positioned between the diffuser and the object, wherein the illuminator is selectively reconfigurable in a plurality of configurations, each configuration corresponding to a manufacturing process that requires visual inspection of the object.

Abstract: A reconfigurable inspection apparatus for inspecting a surface finish of a cylinder bore or other machined surface. The apparatus may include a reconfigurable multi-spindle apparatus supporting a plurality of inspection probes. Each probe may include a laser that directs a laser beam perpendicularly to the machined surface, and a detector positioned at an angle to the laser beam to detect scattered laser light from the surface. The probe may also include a computer system including software that compares the detected scattered light to a scattered light signature from a first-type finishing mark and to a scattered light signature from a second-type finishing mark and determines a condition of the surface finish.

Abstract: A honeycomb multi-stage manufacturing system and associated methods. The system includes a plurality of hexagonal cells defining a honeycomb structure, at least first and second continuous assembly lines defined along selected cell sides for assembling first and second products, and at least one common assembly station for selectively adding a common feature to each of the first and second products. The manufacturing system can be reconfigurable.

Abstract: An integrated reconfigurable multi-stage manufacturing system and associated methods. The system may include a plurality of manufacturing cells, each cell associated with at least one stage of a manufacturing process. The plurality of cells may include a first cell comprising at least one flexible manufacturing station, a second cell comprising at least one reconfigurable manufacturing station, and a third cell comprising at least one reconfigurable inspection machine. The system may also include a plurality of loop conveyors and a plurality of cell gantries. Each loop conveyor may connect at least two neighboring cells and each cell gantry may transport parts from the cell associated with the cell gantry to at least one loop conveyor. In one embodiment, each cell may be hexagonal, and the manufacturing system may have a honeycomb structure.

Abstract: A reconfigurable inspection apparatus for inspecting a surface finish of a cylinder bore or other machined surface. The apparatus may include a reconfigurable multi-spindle apparatus supporting a plurality of inspection probes. Each probe may include a laser that directs a laser beam perpendicularly to the machined surface, and a detector positioned at an angle to the laser beam to detect scattered laser light from the surface. The probe may also include a computer system including software that compares the detected scattered light to a scattered light signature from a first-type finishing mark and to a scattered light signature from a second-type finishing mark and determines a condition of the surface finish.

Abstract: An integrated reconfigurable multi-stage manufacturing system and associated methods. The system may include a plurality of manufacturing cells, each cell associated with at least one stage of a manufacturing process. The plurality of cells may include a first cell comprising at least one flexible manufacturing station, a second cell comprising at least one reconfigurable manufacturing station, and a third cell comprising at least one reconfigurable inspection machine. The system may also include a plurality of loop conveyors and a plurality of cell gantries. Each loop conveyor may connect at least two neighboring cells and each cell gantry may transport parts from the cell associated with the cell gantry to at least one loop conveyor. In one embodiment, each cell may be hexagonal, and the manufacturing system may have a honeycomb structure.

Abstract: A reconfigurable multi-spindle apparatus for use with a machining device in a plurality of configurations across part families. In one embodiment, the reconfigurable multi-spindle apparatus may include at least two spindle head modules, a mechanism for transmitting power between the spindle head modules, and a mechanism for reconfigurably connecting the spindle head modules such that the multi-spindle apparatus is reconfigured from a first configuration to a second configuration across part families. An embodiment of a spindle head module may include two tool holders and a mechanism for adjusting the distance between the tool holders such that the multi-spindle apparatus is reconfigured within a part family.

Abstract: An inspection apparatus, system and method for inspecting parts during a manufacturing process. The apparatus comprises a conveyor line for moving a part during a manufacturing process and a plurality of sensors and cameras mounted on stationary supports around the conveyor line. The conveyor line may be a part of or adjacent to the production line. The sensors measure a characteristic of a first part and produce an inspection output, and can be reconfigured for inspection of at least one different characteristic of a second part or for re-inspection of the first part at a different stage of the manufacturing process. The apparatus may include a computer system that receives the sensor inspection outputs and produces operator-accessible information. The apparatus may include means for identification of the parts. Alternatively, the parts may be stationary and the supports on which the sensors are mounted may be moving relative to the parts.

Abstract: An apparatus comprising a frame, a mobile platform and first and second linearly-actuated slides supported on a base connected to the frame. The first and second slides are movable along a line defining a first axis. The apparatus may include a first driving connector movably coupled to the first slide and to the mobile platform, and a second driving connector movably coupled to the second slide and to the mobile platform, such that the mobile platform is displaceable within at least two degrees of freedom defined by linear motions along the first axis and a second axis, the second axis being coplanar and orthogonal to the first axis. An end effector may be also coupled to the mobile platform, the end effector having an axis aligned in a direction defined by the second axis. The end effector may comprise, for example, a tool or a gripper.

Abstract: An inspection apparatus, system and method for inspecting parts during a manufacturing process. The apparatus comprises a conveyor line for moving a part during a manufacturing process and a plurality of sensors and cameras mounted on stationary supports around the conveyor line. The conveyor line may be a part of or adjacent to the production line. The sensors measure a characteristic of a first part and produce an inspection output, and can be reconfigured for inspection of at least one different characteristic of a second part or for re-inspection of the first part at a different stage of the manufacturing process. The apparatus may include a computer system that receives the sensor inspection outputs and produces operator-accessible information. The apparatus may include means for identification of the parts. Alternatively, the parts may be stationary and the supports on which the sensors are mounted may be moving relative to the parts.

Abstract: A reconfigurable manufacturing system (RMS) having an adjustable structure is designed based upon market demand and can be readily changed from a first desired production capacity to a second desired production capacity to manufacture a desired amount of products from a family of products. The RMS includes a plurality of workstations with reconfigurable machines and computerized numerically controlled (CNC) machines, a control system including a plurality of reconfigurable controllers, as well as a reconfigurable material handling system. The reconfigurable machines may be reconfigurable machine tools having reconfigurable hardware that enables conversion of the machines by, for example, relocating their spindle units. The RMS production capacity is quickly adjusted to market fluctuations in product demand. The RMS functionality is easily adapted to fabrication of new products of the same product family. The RMS possesses certain key characteristics (i.e.

Abstract: A cutting tool insert is mounted on a flexure member that is mounted on the end of a boring bar. The construction of the flexure member is such that it is compliant along a radial axis perpendicular to the direction of tool advancement, but relatively stiff along a feed axis in the direction of tool feed, and along a cutting axis in the direction of tool rotation. Any displacement of the flexure member and cutting tool insert as a result of workpiece engagement or boring bar deflection is sensed by laser detectors. Signals from the laser detectors are coupled to a computer that rotates with the boring bar and are used to provide feedback signals to an actuator in contact with the flexure member. The actuator displaces the flexure member to correct the position of the tool insert.

Abstract: In accordance with the teachings of the present invention, a machine tool assembly is easily reconfigurable to perform single or multiple machining processes on a workpiece so that this machine has exactly the functionality required to perform a given set of machining tasks. The invention allows rapid changes in the machine structure and rapid conversion of the machine by relocating its basic building blocks. The assembly secures a raw workpiece to a table and includes support units that carry at least one single-axis spindle unit. The spindle units are easily attached to one of the support units and are easily movable thereon to perform machining processes from various positions and orientations relative the workpiece. A cutting tool, or other machining tool, is secured to each spindle, which is computer controlled to rotate the tool and stroke it linearly along its axis of rotation. The support units are reconfigurable and can be easily relocated to different positions and orientations about the workpiece.

Abstract: Adaptive control of a system with a human in the loop is accomplished by sensing human operator reactions to a disturbance in the system and characterizing the operator response to the disturbance. The operator response is characterized in one of several forms by predicting a response based on a model quantifying a response based on statistics or merely measuring a response for accumulation of data to be employed by an artificial intelligent system. The disturbance which provides the human operator reaction, is applied or occurs naturally based on other stimulus and is measured by the system. Quantifying the results of the disturbance and the operator response comparison allows selection of a control mode by identifying one or more categories of reaction response or a graduated modification of the control law employed in the system. Various modes or categories for control of the system incorporate different sensitivities on a macro scale or an entirely different control algorithm.

Abstract: A system for compensating for the effects of friction and other forces reting from repeatable disturbances in a servo system or a numerically controlled machine employs a software-based mathematical model which has certain parameters associated therewith. The parameters are calibrated for the specific characteristics of the system using either off-line or on-line methods, and include dynamic correction for continuous correction, as would be required to compensate for forces which disturb a desired motion. The compensation model is implemented in two stages: (i) building a calibrated mathematical model that describes a repeatable disturbance force, such as friction, and (ii) using the model in real time to compensate for the disturbance force. The model provides a compensation signal which is combined with the original controller signal to yield a compensated control signal. The compensation may be in the form of a position offset.

Abstract: A system for producing reliable navigation data for a mobile vehicle, such as a robot, combines multiple range samples to increase the "confidence" of the algorithm in the existence of an obstacle. At higher vehicle speed, it is crucial to sample each sensor quickly and repeatedly to gather multiple samples in time to avoid a collision. Erroneous data is rejected by delaying the issuance of an ultrasonic energy pulse by a predetermined wait-period, which may be different during alternate ultrasonic firing cycles. Consecutive readings are compared, and the corresponding data is rejected if the readings differ by more than a predetermined amount. The rejection rate for the data is monitored and the operating speed of the navigation system is reduced if the data rejection rate is increased. This is useful to distinguish and eliminate noise from the data which truly represents the existence of an article in the field of operation of the vehicle.

Abstract: An inflatable structure, particularly adapted for use in outer space, employs one or more inflatable links which are connected at a base of the structure. A distal end of an outer most link is provided with a gripper assembly which can be remote controlled, and suitable encoders are included to indicate the angular position of each of the links. The motors for driving the at least one link is situated at the base to thereby reduce the mass of the at least one link and correspondingly reduce moments of inertia during operation.