Clamp monitoring system and method for error-proof hose clamp installation

Abstract

The invention discloses a clamp monitoring system and a method for mounting a mistake-proof hose clamp. A method of operating a jig monitoring system includes a system controller that receives confirmation that a working component enters a test package within a workstation. In response to receiving the confirmation, the controller outputs a command prompt to: (1) position the continuity test device at a target clamp position at which the hose clamp attaches the hose to the hose connector of the working component, and (2) activate the test device after being positioned at the target clamp position. The testing device transmits continuity data indicative of electrical continuity of the hose clamp to the controller. The position sensing device transmits position data indicative of the real-time position of the test device to the controller. The controller outputs a notification that the hose clamp is correctly mounted on the working component in response to the continuity status indicating electrical continuity at the hose clamp and the real-time device position being aligned with the target clamp position.

Description

Technical Field

[0001] This disclosure generally relates to fastening devices for motor vehicles. More specifically, aspects of this disclosure relate to systems and methods for verifying the correct installation of hose clamps during the assembly process of automobiles. Background Technology

[0002] Currently manufactured motor vehicles (such as contemporary automobiles) are assembled using a variety of fastening devices, such as bolts, screws, rivets, clips, and clamps. In the assembly of vehicle fuel cell (FCS) systems, hose clamps, for example, are commonly used at different stages of the manufacturing process to connect various fluid conduits, such as the hydrogen fuel feed hose and the barbed hose connector for the stack inlet manifold. During assembly line installation, it is difficult for operators to visually determine whether the hose clamps are installed in the component-specific "target" location, secured with the component-specific "target" orientation, and tightened to the component-specific "target" torque to effectively prevent leaks. Even if properly tightened during the initial assembly process to prevent leaks, the hose clamps may not be installed in the correct location or orientation, potentially leading to leaks during FCS operation. For automotive applications, metal screw-with-hose clamps are used to connect the feed and discharge hoses to complementary barbed hose connectors. While a DC pneumatic torque wrench (commonly referred to as a "nut tightener") can be used to check the correct tightening of screws with hose clamps, it cannot ensure that the clamps are installed in the part specification position and with the part specification orientation. Summary of the Invention

[0003] The following presents an automated monitoring system (with accompanying control logic for verifying the correct installation of fasteners during component assembly), a method for manufacturing such a system, a method for operating such a system, and a motor vehicle manufactured using such a system. For example, and without limitation, the online fixture monitoring system and method automate the verification of hose clamp installation (“hose clamp error prevention”) in a vehicle assembly plant or vehicle component manufacturing setup. The fixture monitoring system and method combine two interrelated subsystems to prevent hose clamp installation errors: (1) an electrical continuity test device for detecting the presence and orientation of the hose clamp; and (2) a precise position-based feedback system for real-time movement and position tracking of the continuity test device to detect the target positioning of the hose clamp. By integrating these two subsystems, the online monitoring system / method helps ensure that the hose clamp is correctly installed at the target location and in a predetermined orientation.

[0004] This disclosure focuses on monitoring system control protocols and processor-executable control logic for error-proofing the installation of fastening devices during component assembly. In an example, a method for operating a fixture monitoring system is proposed to verify the installation of a hose clamp on a working component having a hose and a hose connector. This representative method includes: receiving confirmation from an operator or sensor that the working component has entered a predetermined test envelope within the workstation via a network of resident or remote microcontrollers, central processing units, control modules, programmable logic devices, or controllers / modules / devices (collectively, the "system controller"); for example, in response to receiving the entry confirmation, outputting a target (first) command prompt to the operator or robot unit via the system controller to position the continuous testing device at a predetermined target fixture location, where the hose clamp attaches and seals the hose of the working component to its hose connector; for example... For example, after the testing device is positioned at a predetermined target fixture position, a trigger (second) command prompt is output to the operator or robot unit via the system controller to activate the continuity testing device; for example, continuity data indicating the continuity status at the hose clamp is received from the continuity testing device via the system controller; for example, position data indicating the real-time device position of the continuity testing device is received from one or more position sensing devices via the system controller; and, for example, in response to both the continuity status indicating electrical continuity at the hose clamp and the real-time device position being aligned with the predetermined target fixture position, a notification that the hose clamp is correctly installed on the working part is output to an electronic display device and / or a memory storing a fault log via the system controller.

[0005] This disclosure also relates to a computer-readable medium (CRM) containing controller-executable instructions for error-proofing fastener installation during inter-component assembly. In an example, the non-transitory CRM stores instructions executable by one or more processors of a system controller of a fixture monitoring system. When executed by a processor, the CRM-stored instructions cause the system controller to perform operations including: receiving an entry confirmation instructing a workpiece to enter a predetermined test package within a workstation; outputting a first command prompt to position a continuity testing device at a predetermined target fixture location, where a hose clamp attaches and seals a hose to a hose connector of the workpiece; after being positioned at the predetermined target fixture location, outputting a second command prompt to activate the continuity testing device; receiving continuity data from the continuity testing device indicating a continuity status at the hose clamp; receiving position data from a position sensing device indicating a real-time device position of the continuity testing device; and outputting a notification that the hose clamp is correctly mounted on the workpiece in response to the continuity status indicating electrical continuity at the hose clamp and the real-time device position corresponding to the predetermined target fixture position.

[0006] Another aspect of this disclosure relates to intelligent monitoring systems for error-proofing fastener installation during component assembly, such as clamping a fixture onto a coolant hose or fuel hose of a vehicle fuel cell system. As used herein, the terms "vehicle" and "motor vehicle" are used interchangeably and synonymously include any relevant vehicle platform, such as passenger cars, commercial vehicles, industrial vehicles, off-road and all-terrain vehicles (ATVs), motorcycles, agricultural equipment, aircraft, ships, spacecraft, etc. In the example, the fixture monitoring system includes an electronic continuity testing device that is robotically or manually operated, contacting and detecting electrical continuity at the hose clamp. The fixture monitoring system uses one or more position sensing devices to track the positioning of the continuity testing device within a pre-defined test package within a workstation.

[0007] Continuing the discussion of the foregoing example, the fixture monitoring system is also equipped with a resident or remote system controller that communicates wirelessly or wiredly with the continuity testing device and the position sensing device. The system controller is programmed to receive electronic “entry” confirmation of the workpiece entering the test package of the workstation; in response, the controller outputs a command prompt to: (1) position the continuity testing device at a predetermined target fixture location where the hose clamp attaches and seals the hose to the hose connector of the workpiece; and (2) activate the continuity testing device after being positioned at the target fixture location. Once positioned and activated, the system controller communicates with the continuity testing device to receive continuity data indicating the continuity status at the hose clamp. The system controller also communicates with the position sensing device to receive position data indicating the real-time position of the continuity testing device. If the continuity status indicates electrical continuity at the hose clamp, and the real-time position of the testing device is aligned with the target fixture position (e.g., within a predetermined error range), the system controller responsively outputs a notification that the hose clamp is correctly mounted on the workpiece.

[0008] For any disclosed system, method, and CRM, in response to a continuity status indication of no electrical continuity at the hose clamp (e.g., the continuity test device is activated at the target clamp position but no continuity is detected) and / or the real-time position of the test device is not aligned with the target clamp position (e.g., continuity is detected but the continuity test device is in the wrong position), the system controller may automatically output an alarm indicating that the hose clamp is not properly mounted on the workpiece. In response to the hose clamp not being properly mounted, the system controller may output a rework (third) command prompt to the operator / robot unit to release the hose clamp and reattach it to the hose at a predetermined target clamp position. Alternatively, the position sensing device may include a networked array of wireless radio frequency receivers that receive wireless radio frequency (RF) signals from a wireless transceiver mounted on the continuity test device to triangulate the real-time position of the test device within the test package. Alternatively, the position sensing device may include a networked array of high-resolution cameras; in this case, the position data may include time-series images of the continuity test device within the test package.

[0009] For any of the disclosed systems, methods, and CRMs, the position sensing device can actively track the real-time movement of a continuous test device within the test package. Alternatively, the hose clamp can be a metal strip clamp; in this case, the continuity status can indicate electrical continuity when the metal strip clamp establishes an electrical path between the two wires of the continuous test device. Alternatively, outputting a target (first) command prompt can include: the system controller instructing the graphical user interface (GUI) to display the target clamp position and prompts to the operator at the workstation to position the continuous test device at the target clamp position. Similarly, outputting a trigger (second) command prompt can include: the system controller instructing the GUI to display prompts simultaneously or separately to the workstation operator to manually activate the continuous test device after it has been positioned at the target clamp position. For fully automated systems, the system controller can output target and trigger command prompts to the robotic work cell to position and activate the continuous test device.

[0010] For any of the disclosed systems, methods, and CRMs, the system controller can output a connection and seal (third) command prompt to the operator / robot after receiving an entry confirmation and before transmitting the target and triggering the command prompt, to connect the hose to the hose connector and / or secure the hose clamp to the hose. After outputting the connection and seal command prompt, the system controller can receive an installation confirmation instructing the hose clamp to be secured to the hose. Alternatively, entry confirmation instructing the working part to enter the test package at the workstation can be received by the system controller from a proximity sensor, limit switch, or user input device at the workstation. The disclosed concepts can be used in both vehicle and non-vehicle applications and can be implemented to prevent incorrect installation of various fastening devices. Furthermore, the disclosed hose clamps can take various suitable form factors, including belt clamps, single-wire and multi-wire clamps, spring clamps, ear clamps, quick-release clamps, hook and loop clamps, etc.

[0011] The present invention also discloses the following technical solutions:

[0012] Solution 1. A method for operating a clamp monitoring system, the clamp monitoring system being used to verify the installation of a hose clamp on a working component having a hose and a hose connector, the method comprising:

[0013] The system controller of the fixture monitoring system receives an entry confirmation indicating that the working component enters a predetermined test package within the workstation.

[0014] In response to receiving the entry confirmation, a first command prompt is output via the system controller to position the continuous testing device at a predetermined target clamp position, wherein the hose clamp attaches and seals the hose to the hose connector of the working component at the predetermined target clamp position.

[0015] After being positioned at the predetermined target fixture location, the system controller outputs a second command prompt to activate the continuous testing device;

[0016] The system controller receives continuity data from the continuity testing device, indicating the continuity status at the hose clamp;

[0017] The system controller receives position data from the position sensing device, indicating the real-time device position of the continuous testing device; and

[0018] In response to the continuity status indicating electrical continuity at the hose clamp and the real-time device position being aligned with the predetermined target clamp position, a notification is output via the system controller that the hose clamp is correctly installed on the working component.

[0019] Option 2. The method according to Option 1 further includes: in response to the continuity status indicating no electrical continuity at the hose clamp and / or the real-time device position not being aligned with the predetermined target clamp position, outputting an alarm via the system controller that the hose clamp is not properly installed on the working component.

[0020] Option 3. The method according to Option 2 further includes: in response to the hose clamp not being properly installed on the working component, outputting a third command prompt via the system controller to release the hose clamp and reattach the hose clamp to the hose at the predetermined target clamp position.

[0021] Option 4. According to the method of Option 1, wherein the position sensing device includes a networked array of wireless radio frequency receivers, the wireless radio frequency receivers being configured to receive wireless radio frequency signals from the wireless transceiver of the continuity test device, thereby triangulating the real-time device position of the continuity test device.

[0022] Option 5. According to the method of Option 1, wherein the position sensing device includes a networked array of high-resolution cameras, and the position data includes time-series images of the continuity testing device within the test package.

[0023] Option 6. The method according to Option 1 further includes: tracking the real-time movement of the continuity testing device within the test package via the position sensing device.

[0024] Option 7. The method according to Option 1, wherein the hose clamp includes a metal strip clamp, and wherein the continuity state indicates electrical continuity at the hose clamp when the metal strip clamp establishes an electrical path between two wires of the continuity testing device.

[0025] Option 8. According to the method of Option 1, wherein outputting the first command prompt includes: the system controller commands the graphical user interface to display the predetermined target fixture position and prompts to the operator at the workstation in order to locate the continuity testing device.

[0026] Option 9. According to the method of Option 8, the output of the second command prompt includes: the system controller instructing the graphical user interface to display a prompt simultaneously or individually to the operator at the workstation in order to activate the continuity testing device.

[0027] Option 10. According to the method of Option 1, wherein the system controller outputs the first command prompt and the second command prompt to the robot working unit in order to locate and activate the continuity testing device.

[0028] Option 11. The method according to Option 1 further includes: in response to receiving the entry confirmation, and before transmitting the first command prompt and the second command prompt, outputting a third command prompt via the system controller to connect the hose to the hose connector and / or secure the hose clamp to the hose.

[0029] Option 12. The method according to Option 1 further includes: receiving installation confirmation via the system controller indicating that the hose clamp is fixed to the hose.

[0030] Option 13. According to the method of Option 1, the entry confirmation is received via the system controller from a proximity sensor, a limit switch, or a user input device at the workstation.

[0031] Option 14. A non-transitory computer-readable medium storing instructions executable by a system controller of a clamp monitoring system for verifying the installation of a hose clamp on a working part having a hose and a hose connector, the instructions, when executed, causing the system controller to perform operations including:

[0032] Receive an entry confirmation indicating that the working component enters a pre-determined test package within the workstation;

[0033] Output a first command prompt to position the continuous testing device at a predetermined target clamp position, wherein the hose clamp attaches and seals the hose to the hose connector of the working component at the predetermined target clamp position;

[0034] After being positioned at the predetermined target fixture location, a second command prompt is output to activate the continuous testing device;

[0035] Receive continuity data from the continuity testing device, indicating the continuity status at the hose clamp;

[0036] Receive position data from the position sensing device indicating the real-time device position of the continuous testing device; and

[0037] In response to the continuity status indicating electrical continuity at the hose clamp and the real-time device position corresponding to the predetermined target clamp position, a notification is output that the hose clamp is correctly installed on the working component.

[0038] Option 15. A clamp monitoring system for verifying the installation of a hose clamp on a working part having a hose and a hose connector, the clamp monitoring system comprising:

[0039] A continuity testing device configured to contact and detect electrical continuity at the hose clamp;

[0040] A position sensing device configured to detect the position of the continuous test apparatus within a pre-defined test package within a workstation;

[0041] A system controller, communicatively connected to the continuous testing apparatus and the position sensing device, is programmed to:

[0042] Receive entry confirmation instructing the working component to enter the predetermined test package within the workstation;

[0043] In response to receiving the entry confirmation, a first command prompt is output to position the continuity testing device at a predetermined target clamp position, wherein the hose clamp attaches and seals the hose to the hose connector at the predetermined target clamp position;

[0044] After being positioned at the predetermined target fixture location, a second command prompt is output to activate the continuous testing device;

[0045] Receive continuity data from the continuity testing device, indicating the continuity status at the hose clamp;

[0046] Receive position data indicating the real-time device position of the continuous testing device from the position sensing device; and

[0047] In response to the continuity status indicating electrical continuity at the hose clamp and the real-time device position being aligned with the predetermined target clamp position, a notification is output that the hose clamp is correctly installed on the working component.

[0048] Option 16. The clamp monitoring system according to Option 15, wherein the system controller is further programmed to output an alarm that the hose clamp is not properly installed on the working part in response to the continuity status indicating that there is no electrical continuity at the hose clamp and / or the real-time device position is not aligned with the predetermined target clamp position.

[0049] Option 17. The clamp monitoring system according to Option 15, wherein the system controller is further programmed to output a third command prompt to the operator at the workstation in response to the hose clamp not being properly installed on the working component, so as to reattach the hose clamp to the hose at the predetermined target clamp position.

[0050] Option 18. The clamp monitoring system according to Option 15, wherein the hose clamp includes a metal strip clamp, and wherein the continuity state indicates the electrical continuity at the hose clamp when the metal strip clamp establishes an electrical path between two wires of the continuity testing device.

[0051] Option 19. The fixture monitoring system according to Option 15, wherein outputting the first command prompt includes: the system controller commanding the graphical user interface to display the predetermined target fixture position and prompts to the operator at the workstation in order to locate the continuity testing device.

[0052] Option 20. The clamp monitoring system according to Option 15, wherein the system controller is further programmed to output a third command prompt in response to receiving the entry confirmation, to connect the hose to the hose connector and / or secure the hose clamp to the hose.

[0053] The foregoing summary does not represent every embodiment or aspect of this disclosure. Rather, it merely provides an overview of some novel concepts and features set forth herein. These features and advantages, along with other features and accompanying advantages of this disclosure, will become apparent when taken in conjunction with the accompanying drawings and appended claims, from the examples set forth below and specific embodiments of representative modes for carrying out this disclosure. Therefore, this disclosure expressly includes any and all combinations and sub-combinations of the elements and features presented above and below. Attached Figure Description

[0054] Figure 1 This is a perspective view of a representative motor vehicle with an insert schematic diagram of a vehicle fuel cell system (FCS), which enables various aspects of this disclosure to be practiced.

[0055] Figure 2 This is a perspective view of a representative clamp monitoring system for mis-installing hose clamps into a fuel cell system of a motor vehicle, according to various aspects of this disclosure.

[0056] Figure 3 The diagram illustrates a flowchart of a representative manufacturing control protocol for error-proof installation of a hose clamp into a motor vehicle according to various aspects of this disclosure. This manufacturing control protocol may correspond to instructions stored in a memory, which may be executed by a resident or remote microcontroller, control module, logic circuit or other integrated circuit (IC) device or network of circuit / module / microprocessor / IC devices (collectively, the “controller”).

[0057] This disclosure is applicable to various modifications and alternatives, and representative embodiments of this disclosure have been illustrated by way of example in the accompanying drawings and will be described in detail herein. However, it should be understood that the novel aspects of this disclosure are not limited to the specific forms illustrated in the foregoing enumerations in the drawings. Rather, this disclosure covers all modifications, equivalents, combinations, arrangements, groupings, and alternatives falling within the scope of this disclosure, the scope of which is defined, for example, by the appended claims. Detailed Implementation

[0058] This disclosure is open to various embodiments. Representative embodiments of this disclosure are shown in the accompanying drawings and described in detail herein. It should be understood that these embodiments are provided as examples of the principles of the disclosure and not as limiting the broad aspects of this disclosure. To this extent, elements and limitations (e.g., described in the abstract, introduction, summary, description of drawings, and detailed description but not expressly set forth in the claims) should not be incorporated into the claims individually or collectively by implication, inference, or otherwise. Furthermore, the terms “first,” “second,” “third,” etc., in the specification or claims are not in themselves intended to establish a sequence or numerical limitation; unless specifically stated otherwise, these designations may be used to simplify reference to similar features in the specification and drawings and to distinguish between similar elements in the claims.

[0059] For the purposes of this disclosure, unless otherwise stated: singular includes plural, and vice versa (e.g., the indefinite articles “a” and “one” should generally be understood to mean “one or more”); the words “and” and “or” should be connected and separate; the words “any” and “all” should both mean “any and all”; the words “including,” “contains,” “includes,” “has,” etc., should each mean “including but not limited to.” Furthermore, approximate words (e.g., “about,” “almost,” “substantially,” “usually,” “approximately,” etc.) can each be used herein to mean, for example, “in,” “nearly,” or “within 0-5% of,” or “within acceptable manufacturing tolerances,” or any logical combination thereof. Finally, directional adjectives and adverbs (e.g., forward, aft, inside, outside, starboard, port, vertical, horizontal, up, down, forward, aft, left, right, etc.) can be relating to the motor vehicle, for example, the forward direction of travel of the motor vehicle when it is operatively oriented on a level driving surface.

[0060] Referring now to the accompanying drawings, where similar reference numerals refer to similar features throughout the various views, Figure 1 A representative motor vehicle, generally designated 10 and depicted herein as a sedan-style electric vehicle for the purposes of discussion, is shown. The illustrated vehicle 10 (also referred to herein simply as a "motor vehicle" or "vehicle") is merely an example application utilizing which various aspects of this disclosure can be practiced. In the same context, incorporating the present concept into the illustrated clamp monitoring system for error-proof hose clamp installation should be understood as a non-limiting implementation of the disclosed features. Thus, it will be understood that the novel features of this disclosure can be implemented by other monitoring system architectures to prevent the installation of various fastening devices, can be incorporated into any logically related type of motor vehicle, and can be used equally for both automotive and non-automotive applications. Furthermore, only selected parts of the motor vehicle and clamp monitoring system are shown and described in detail herein. However, the vehicles and systems discussed below may include a large number of additional and alternative features, as well as other available peripheral hardware, for performing the various methods and functions of this disclosure.

[0061] Figure 1 The vehicle body 12 of the car 10 contains a fuel cell system (FCS) 14 for powering a prime mover, such as an electric motor generator unit (MGU) 16, which is operable to drive one or more of the vehicle's road wheels 18, thereby propelling the vehicle 10. Figure 1The fuel cell system 14 is equipped with one or more fuel cell stacks 20, each stack comprising proton exchange membrane (PEM) fuel cells 22 stacked and electrically connected to each other. Each fuel cell 22 is a multilayer structure having an anode side 24 and a cathode side 26, which are separated by a proton-conductive perfluorosulfonic acid membrane 28. An anode diffusion medium layer 30 is located on the anode side 24 of the PEMFC 22, wherein an anode catalyst layer 32 is interposed between the membrane 28 and the corresponding diffusion medium layer 30 and operatively connected to both. Adjacent to the anode layers 30 and 32 is a cathode diffusion medium layer 34 provided on the cathode side 26 of the PEMFC 22. A cathode catalyst layer 36 is interposed between the membrane 28 and the corresponding diffusion medium layer 34 and operatively connected to both. The two catalyst layers 32 and 36 cooperate with the membrane 28 to at least partially define a membrane electrode assembly (MEA) 38. The diffusion medium layers 30 and 34 are porous structures that provide fluid inlet transport to MEA 38 and fluid outlet transport from MEA 38.

[0062] An anode flow field plate (or "first plate") 40 is located on the anode side 24, in close contact with the anode diffusion medium layer 30. Similarly, a cathode flow field plate (or "second plate") 42 is located on the cathode side 26, in close contact with the cathode diffusion medium layer 34. Coolant flow channels 44 pass through each plate 40 and 42 to allow cooling fluid to flow through the fuel cell 22. Fluid inlet ports and manifolds direct hydrogen-rich fuel and oxidant to corresponding channels within the anode and cathode flow field plates 40, 42. The central active region of the anode plate 40 facing the proton conductive membrane 28 can be constructed by an anode flow field consisting of serpentine flow channels, which is used to distribute hydrogen on the opposite side of the membrane 28. The MEA 38 and plates 40, 42 can be stacked together between stainless steel clamps and single-end plates (not shown). These clamps can be electrically insulated from the end plates by gaskets or dielectric coatings.

[0063] Hydrogen (H2) inlet flow (whether gaseous, concentrated, entrained, or otherwise) is delivered from a hydrogen source, such as fuel storage tank 46, to the anode side 24 of fuel cell stack 20 via a fluid injector 47 connected to a (first) fluid inlet conduit or hose 48. Anode effluent exits stack 20 via a (first) fluid outlet conduit or hose 50. Although illustrated on the anode side of the stack, a compressor or pump 52 pushes cathode inlet flow (such as ambient air and / or concentrated gaseous oxygen (O2)) to the cathode side 26 of stack 20 via a (second) fluid inlet line or manifold 54. Cathode effluent exits stack 20 via a (second) fluid outlet conduit or hose 56. Electricity generated by fuel cell 22 and output through fuel cell system 14 can be stored in rechargeable energy storage system (RESS) 80 via traction battery pack 82 within the vehicle.

[0064] Figure 1The fuel cell system 14 may also include a thermal subsystem operable during pretreatment, break-in, post-treatment, etc., for controlling the temperature of the fuel cell stack 20. A coolant pump 58 pumps cooling fluid to the fuel cell stack 20 via a coolant circulation 60 and into coolant channels 44 in each cell 22. A radiator 62 and optional heater 64 may be fluidly coupled to the coolant circulation 60 to maintain the stack 20 at a desired operating temperature. A (first) temperature sensor 66 can monitor the temperature of the coolant at the coolant inlet of the fuel cell stack 20, and a (second) temperature sensor 68 can measure the temperature of the coolant at the coolant outlet of the stack 20. An electrical connector or cable 74 connects the fuel cell stack 20 to an electrical load 76, which can be used to draw current from each cell 22 in the stack 20. A voltage / current sensor 70 is operable to measure the fuel cell voltage and / or current passing through the fuel cells 22 in the stack 20.

[0065] The programmable electronic control unit (ECU) 72 helps control the operation of the fuel cell system 14. For example, the ECU 72 can receive a temperature signal T1 from temperature sensors 66, 68, which indicates the operating temperature of the fuel cell stack 20, and can correspondingly issue a command signal C1 to regulate the operation of the stack 20. The ECU 72 can also receive a voltage signal V1 from a voltage / current sensor 70, and can correspondingly issue a command signal C2 to regulate the operation of the hydrogen storage tank 46 and / or the compressor / pump 52, thereby adjusting the electrical output of the stack 20. Figure 1 The ECU 72 can also receive coolant temperature signals T2 from temperature sensors 66 and 68, and correspondingly issue command signals S3 to regulate the operation of the fuel cell's thermal system. Additional sensor signals S... N It can be received by ECU72 and additional control commands C can be attached. N The ECU 72 can issue commands to control any other subsystems or components described herein. The ECU 72 can issue command signals to transfer the released hydrogen and liquid H2O from the cathode side 26 through the discharge conduit 56 and to the storage tank 78. Figure 1 Hydrogen and water can combine here with hydrogen discharged from the anode through the fluid discharge conduit / hose 50.

[0066] Figure 1The traction battery pack 82 may comprise an array of rechargeable lithium-ion (secondary) battery modules 84. The disclosed concept is similarly applicable to other forms of electrical storage, including nickel-metal hydride (NiMH) batteries, solid-state (SS) batteries, lithium metal and lithium-sulfur batteries, and other applicable types of rechargeable electric vehicle batteries (EVBs). Each battery module 84 may comprise a cluster of electrochemical battery cells, such as prismatic, cylindrical, or pouch-type lithium-ion (Li-ion) or lithium-ion polymer battery cells 86. To boost the voltage output of the vehicle's FCS, a corresponding DC-to-DC boost converter (DC CON) may be electrically inserted between the fuel cell stack 20 and the RESS 80.

[0067] To ensure uninterrupted and efficient operation of the fuel cell system 14, it is crucial that all fluid delivery conduits are securely attached and sealed to their respective fluid ports to maintain a continuous, error-free fluid flow. For example, extreme care should be taken when installing the FCS fuel and coolant feed lines to avoid high-risk system failures such as coolant system leaks leading to reduced coolant flow or coolant ionization. Original equipment manufacturers (OEMs) can therefore implement additional "fail-safe" measures during the assembly process to ensure that hose and hose clamp installation is performed according to specific engineering standards ("compliant with specifications"). Many FCS architectures use screw-and-band (worm gear) hose clamps to attach and seal the FCS coolant / fuel hoses to the convex barb hose connector, allowing the operator installing the clamp to record torque values ​​as proof that the clamp and hose have been installed. However, this procedure cannot guarantee that the hose clamps are installed correctly, as the clamps may be improperly positioned on top of the connector barbs, or worse, installed off the hose fitting. To prevent errors, the installation of spring-loaded hose clamps may require verification that the hose clamps are installed at the specific "target" position of the component and fixed in the specific "target" orientation of the component.

[0068] The following discussion concerns automated monitoring systems with accompanying processor-executable control logic for verifying the correct installation of fasteners during the assembly process between components. For example, and without limitation, online fixture monitoring systems and methods utilize precise position identification and continuity analysis to automate the error-proofing of hose clamps in vehicle assembly plants. Precise position identification can be achieved in various ways, including: (1) vision-based systems using a networked array of static stereo cameras for triangulation of tool position and orientation; (2) radial, linear, and axial sensors for tracking the position and orientation of the end effector of an articulated robotic arm; and (3) RF tethers for tool mounting for real-time tracking of tool position and orientation. Continuity analysis can be achieved by applying a metering current between two electrical test probes to measure resistance, for example, to confirm that the probes are contacting a metal clamp rather than a polymer hose. In a representative configuration, the robotic work cell includes an articulated robotic arm automated by a controller, having an end effector supporting continuity test probes, and an array of position identification sensors to track the real-time or near-real-time position and orientation of the end effector. The probes can be spaced approximately 5 to 10 millimeters (mm) and can be spring-loaded to accommodate different geometries of the hose clamps. For each FCS assembly, component-specific target positions of one or more hose clamps can be programmed by the manufacturing team.

[0069] Turn Figure 2 This demonstrates the use of a metal spring-type hose clamp 102 for error-proof installation into a fuel cell system 114 (e.g., Figure 1 An example of a gripper monitoring system 100 in a vehicle (FCS14). According to the illustrated example, the gripper monitoring system 100 uses a manually operated electronic continuity test device 104 with a pair of electrical test leads 106 designed to physically contact and simultaneously transmit current through a flexible gripper 102 to detect electrical continuity across the gripper 102. As mentioned above, the flexible gripper 102 can be a metal spring-type band gripper, for example, to eliminate the need for checking the correct tightening of screw-with-flexor grippers. The continuity test device 104 can detect electrical continuity at the flexible gripper 102 when the metal band of the gripper establishes an electrical path (i.e., completes the circuit) between the two test leads 106. For ease of use and freedom of movement, it is preferable that the continuity test device 104 be a wireless and battery-powered handheld device. It is contemplated that the continuity test device 104 can be integrated into robot end effectors for floor, counter, or gantry-mounted robot components for a fully automated system architecture.

[0070] Figure 2The fixture monitoring system 100 also utilizes a precise position identification subsystem to actively track the real-time or near-real-time positioning of the continuous test apparatus 104 within a predetermined test package 108 embedded within an operator workstation 110, such as a production line-side workstation module in a vehicle assembly plant. While not inherently limiting, the position sensing subsystem can typically be a networked array of position sensing devices 112 that generate position data indicating the real-time position and (if desirable) real-time movement and orientation of the continuous test apparatus. For at least some applications, each sensing device 112 can be a radio frequency (RF) receiver / transceiver that receives and optionally transmits RF signals to or from a wireless RF transmitter / transceiver tether 124 mounted on or within the continuous test apparatus 104. Using the wireless signals received from the tool-mounted tether 124 via the RF transmitter / transceiver sensing devices 112, the central system controller 118 of the workstation operator interface unit 116 triangulates the real-time device position of the continuous test apparatus 104. Alternatively, the position recognition subsystem can be a vision-based system, wherein the position sensing device 112 is a networked array of high-resolution cameras that can continuously track the movement of the continuous testing device 104. In this case, the position data output by the high-resolution camera sensing device 112 may include time-series images of the continuous testing device 104 within the test package 108; these images can be preprocessed, filtered, and fused to derive the real-time device position of the continuous testing device 104.

[0071] Continue to refer to Figure 2 The workstation operating interface unit 116 can be a mobile computing device on the production line side, providing hybrid services, either independently or through communication with other network devices. This interface unit 116 can typically consist of one or more processors, each of which can be implemented as a discrete microprocessor, application-specific integrated circuit (ASIC), or dedicated control module. The fixture monitoring system 100 can provide centralized system control via a central system controller 118, which is operatively coupled to a touchscreen display device 122 and one or more electronic storage devices 120. Each of the storage devices 120 can be in the form of CD-ROM, disk, IC device, solid-state drive (SSD) memory, hard disk drive (HDD) memory, flash memory, semiconductor memory (e.g., various types of RAM or ROM), etc. The central system controller 118 of the workstation operating interface unit 116 can receive information from the FCS 114 working parts via proximity sensors or limit switches (in... Figure 2 The test package 108 is designated as 126) or is accessed by the operator via touch screen display device 122 or other suitable user input device to workstation 110 for confirmation.

[0072] Next reference Figure 3 The flowchart, according to various aspects of this disclosure, describes approximately 200 improved methods or control protocols for fastening devices (such as... Figure 2 The hose clamp 102 in the middle is installed to the working part (e.g., the hose clamp) to prevent mis-installation. Figure 1 and 2 On fuel cell systems 14 and 114 in the middle. Figure 3 Some or all of the operations illustrated in the diagram and described in further detail below may represent algorithms corresponding to non-transitory, processor-executable instructions stored, for example, in main, secondary, or remote memory (e.g., ...). Figure 2 These instructions can be, for example, from an electronic controller, processing unit, dedicated control module, logic circuit or other module or device or network of controller / module / device (e.g., ...). Figure 2 The central system controller 118 in the system executes any or all of the functions described above and below in connection with the concept of this disclosure. It should be understood that the order of execution of the illustrated operation blocks can be changed, additional operation blocks can be added, and some operations described herein can be modified, combined, or eliminated.

[0073] Method 200 in Figure 3 Beginning at end block 201, it has memory-stored processor-executable instructions for initializing the inter-part assembly procedure, and features an integrated fastener installation error-proofing control protocol. This routine can be initialized in real-time, near real-time, continuous, systematic, occasional, and / or predetermined time intervals, such as every 10 or 100 milliseconds during operation of operator workstation 110. Alternatively, end block 201 can be initialized in response to a user command prompt (e.g., via telematics input control input), a resident workstation controller prompt (e.g., via output from central system controller 118), or a broadcast prompt signal received from a centralized back-office (BO) plant server center. Upon completion... Figure 3 After some or all of the control operations presented in the process, method 200 can proceed to end block 229 and temporarily terminate, or it can selectively cycle back to end block 201 and run in a continuous loop.

[0074] From end block 201, proceed to the confirmation data input block 203. Method 200 verifies that the working component has entered the pre-defined test package within the workstation. As discussed above... Figure 2As mentioned earlier, the proximity sensor or limit switch 126 can detect the entry of the fuel cell system 114 into the workstation test package 108 and output sensor data indicating this to the central system controller 118. Alternatively, the workstation operator can confirm the entry of the fuel cell system 114 by selecting a virtual radio or binary button on the touchscreen display 122. Entry confirmation may also require verifying that the received working component is both: (1) the correct component type, and (2) set in the "zeroing" target component orientation within the test package 108.

[0075] Upon receiving a workpiece, the workstation operator may be prompted to complete a predefined task or task set associated with that specific workstation, as indicated by workstation task display block 205. For example, the central system controller 118 may respond to receipt of electronic entry confirmation by commanding the touchscreen display device 122 to display a prompt or series of prompts to the workstation operator, indicating that FCS 114 has entered test package 108 to: first, loosely position the hose clamp 102 around the middle portion of the convex barbed hose connector 130 of FCS 114; second, press-fit the open end of the coolant feed hose 128 onto the barbed open end of the hose connector 130; and third, secure the hose clamp 102 to the coolant feed hose 128 with a part-specific "target" position and part-specific "target" orientation. Once the displayed connection and sealing task is complete, the central system controller 118 may receive user input confirmation indicating that one or more of the requested tasks have been completed, as indicated by task completion display block 207. It is foreseeable that process blocks 205 and 207 may be omitted in whole or in part from method 200, for example, in a scenario where FCS 114 is received at workstation 110 (where hose 128 and / or hose clamp 102 have been installed).

[0076] After receiving the working component (block 203) and confirming that the hose clamp has been installed on the working component (block 207), method 200 can be executed responsively. Figure 3The target position subroutine 209 positions the continuous testing device at a predetermined target fixture location. A designed hose clamp attaches and seals the corresponding hose to its corresponding hose connector on the main working component at this predetermined target fixture location. For fully automated systems, the central system controller 118 can issue target control command sequences to the main control module of the robot unit or directly to the servo motor assembly, managing the movement of the robotic arm to move the continuous testing device with integrated end effector to a component-specific target location within the 3D space of the test package. For manual applications, the central system controller 118 can command the graphical user interface (GUI) of the touchscreen display 122 to display one or more predetermined target fixture locations being tested, accompanied by display prompts to move the continuous testing device to each displayed target location.

[0077] In conjunction with the target position subroutine 209, method 200 can execute the tool activation subroutine 211 to activate the continuous testing device at each predetermined target fixture position. For fully automated systems, the central system controller 118 can issue trigger control commands to the main control module of the robot unit or directly to the continuous testing device with integrated end effector to activate the device at each component-specific target position. For manual applications, the central system controller 118 can command the graphical user interface (GUI) of the touchscreen display device 122 to display (simultaneously with or separately from the target control command) prompts to the operator at the workstation to activate the continuous testing device 104 at each target position.

[0078] Figure 3 Method 200 proceeds from tool activation subroutine 211 to fault installation decision block 213 to determine whether each hose clamp is correctly installed on the working part. As mentioned above, clamp monitoring system 100 can implement a two-part approach for error-proof hose clamp installation, combining precise position identification with electrical continuity analysis. According to the former, central system controller 118 can communicate with one or more position sensing devices, such as... Figure 2 A networked array of position sensing devices 112 is used to receive position data indicating the real-time position of the continuous testing device 104. For at least some applications, actively tracking the real-time movement, positioning, and orientation of the continuous testing device 104 may be desirable, including detecting the arrival of the continuous testing device 104 at each target location. Meanwhile, Figure 2 The central system controller 118 can communicate with the continuity test apparatus 104 to receive continuity data (e.g., binary yes / no readings or resistance readings of zero (0) ohms or open circuit (OL)) indicating the continuity status at the hose clamp 102.

[0079] Decision block 213 will return a negative or incorrect installation result if one or both of the following exist: (1) the continuity status output by continuity test device 104 indicates no electrical continuity at the hose clamp; and (2) when activated, the real-time position of continuity test device 104 is substantially misaligned with the predetermined target clamp position of the hose clamp. If the tested hose clamp is incorrectly installed (block 213 = No), then Figure 3 Method 200 can responsively execute fault flag data storage block 215 and set a fault flag in resident memory device 120 to indicate that the tested hose clamp was not detected or was in an unacceptable position. In series with setting the fault flag stored in memory, method 200 can responsively execute fault clamp display block 217 and output visual, audible and / or tactile alarms indicating that the tested hose clamp is not properly installed on the working part, for example via continuous testing device 104 and / or workstation operator interface unit 116.

[0080] After an alarm indicating that the output hose clamp is not installed correctly, Figure 3 Method 200 can execute a timeout loop exit 219 and determine whether the total number of incorrectly installed clamp rejections for a given hose clamp exceeds the maximum allowable number of clamp reworks. For example, a workstation operator may be given three (3) opportunities to attempt to rework and repair an incorrectly installed hose clamp; if the clamp is rejected a fourth time, method 200 may time out. If the total number of clamp rejections for the main hose clamp exceeds the maximum allowable number of clamp reworks (block 219 = Yes), method 200 may exit the fault installation loop and temporarily terminate at end block 229. If not (block 219 = No), method 200 may execute a clamp rework subroutine 221 and attempt to correct the incorrectly installed hose clamp. For example, Figure 2 The central system controller 118 can respond to a misinstallation of the hose clamp 102 on the FCS 114 by commanding the touchscreen display 122 to prompt the workstation operator to release the hose clamp 102, reposition the hose clamp 102 onto the coolant feed hose 128 and hose connector 130, and reattach the hose clamp 102 to the hose 128 at a predetermined target clamp position. For a fully automated system, the above assembly process can be performed by the articulated robotic arm and robotic end effector of the robotic work cell. Once the hose clamp is reworked, method 200 will cycle back to the tool activation subroutine 211 and fault installation decision block 213.

[0081] Decision block 213 will return a positive or correct installation result if both of the following are true: (1) the continuity status output by the continuity test device 104 indicates that there is electrical continuity at the tested hose clamp, and (2) when activated, the real-time position of the continuity test device 104 is substantially aligned with the predetermined target clamp position of the hose clamp (e.g., within acceptable manufacturing tolerances). If the tested hose clamp is installed correctly (block 213 = YES), Figure 3 Method 200 can responsively execute the pass flag data storage block 223 and set a pass flag in the resident memory device 120, indicating that the tested hose clamp has been detected and is in an unacceptable position. In series with setting the pass flag stored in memory, method 200 can responsively execute the accept clamp display block 225 and output a visual, audible, and / or tactile alarm, for example via the continuous testing device 104 and / or the workstation operator interface unit 116, indicating that the tested hose clamp is correctly mounted on the working part. At this point, method 200 can execute the part release data output block 227 and alert the workstation operator or robot work unit that the working part has been approved to leave the workstation. Method 200 can then be temporarily terminated at end block 229.

[0082] In some embodiments, aspects of this disclosure may be implemented by computer-executable program instructions, such as program modules commonly referred to as software applications or application programs, which are executed by any controller or controller variant described herein. Software may include (by non-limiting example) routines, programs, objects, components, and data structures that perform specific tasks or implement specific data types. Software may form interfaces to allow a computer to react to input sources. In response to received data in conjunction with a source receiving data, software may also cooperate with other code segments to initiate various tasks. Software may be stored on any of a variety of storage media, such as CD-ROMs, disks, and semiconductor memories (e.g., various types of RAM or ROM).

[0083] Furthermore, aspects of this disclosure can be practiced with various computer systems and computer networks, including multiprocessor systems, microprocessor-based or programmable consumer electronics devices, minicomputers, mainframe computers, and so on. Additionally, aspects of this disclosure can be practiced in distributed computing environments where tasks are executed via resident and remote processing devices connected through communication networks. In distributed computing environments, program modules can reside on both local and remote computer storage media, including memory storage devices. Therefore, aspects of this disclosure can be implemented in computer systems or other processing systems in combination with various hardware, software, or combinations thereof.

[0084] Any method described herein may include machine-readable instructions for execution by: (a) a processor, (b) a controller, and / or (c) any other suitable processing means. Any algorithm, software, control logic, protocol, or method disclosed herein may be implemented as software stored on a tangible medium such as, for example, flash memory, solid-state drive (SSD) memory, hard disk drive (HDD) memory, CD-ROM, digital versatile disc (DVD), or other storage devices. The entire algorithm, control logic, protocol, or method, and / or its components, may alternatively be executed by means other than a controller, and / or may be embedded in firmware or dedicated hardware in a manner that is available (e.g., implemented by application-specific integrated circuits (ASICs), programmable logic devices (PLDs), field-programmable logic devices (FPLDs), discrete logic, etc.). Furthermore, while a particular algorithm may be described with reference to the flowcharts and / or workflow diagrams depicted herein, many other methods for implementing the example machine-readable instructions may be used alternatively.

[0085] Various aspects of this disclosure have been described in detail with reference to the illustrated embodiments; however, those skilled in the art will recognize that many modifications can be made thereto without departing from the scope of this disclosure. This disclosure is not limited to the precise construction and composition disclosed herein; any and all modifications, variations, and alterations apparent from the foregoing description are within the scope of this disclosure as defined by the appended claims. Furthermore, this concept clearly includes any and all combinations and sub-combinations of the foregoing elements and features.

Claims

1. A method for operating a clamp monitoring system, the clamp monitoring system being used to verify the installation of a hose clamp on a working component having a hose and a hose connector, the method comprising: The system controller of the fixture monitoring system receives an entry confirmation indicating that the working component enters a predetermined test package within the workstation. In response to receiving the entry confirmation, a first command prompt is output via the system controller to position the continuous testing device at a predetermined target clamp position, wherein the hose clamp attaches and seals the hose to the hose connector of the working component at the predetermined target clamp position. After being positioned at the predetermined target fixture location, the system controller outputs a second command prompt to activate the continuous testing device; The system controller receives continuity data from the continuity testing device, indicating the continuity status at the hose clamp; The system controller receives position data from the position sensing device, indicating the real-time device position of the continuous testing device; as well as In response to the continuity status indicating electrical continuity at the hose clamp and the real-time device position being aligned with the predetermined target clamp position, a notification is output via the system controller that the hose clamp is correctly installed on the working component.

2. The method according to claim 1, further comprising: In response to the continuity status indicating no electrical continuity at the hose clamp and / or the real-time device position not being aligned with the predetermined target clamp position, an alarm is output via the system controller that the hose clamp is not properly installed on the working component.

3. The method according to claim 2, further comprising: In response to the hose clamp not being properly installed on the working part, a third command prompt is output via the system controller to release the hose clamp and reattach the hose clamp to the hose at the predetermined target clamp position.

4. The method of claim 1, wherein the position sensing device comprises a networked array of wireless radio frequency receivers configured to receive wireless radio frequency signals from a wireless transceiver of the continuity test apparatus, thereby triangulating the real-time device position of the continuity test apparatus.

5. The method of claim 1, wherein the position sensing device comprises a networked array of high-resolution cameras, and the position data comprises time-series images of the continuity testing device within the test package.

6. The method of claim 1, further comprising: The position sensing device tracks the real-time movement of the continuous testing device within the test package.

7. The method of claim 1, wherein the hose clamp comprises a metal strip clamp, and wherein the continuity state indicates electrical continuity at the hose clamp when the metal strip clamp establishes an electrical path between two wires of the continuity testing device.

8. The method of claim 1, wherein outputting the first command prompt comprises: The system controller commands the graphical user interface to display the predetermined target fixture position and prompts to the operator at the workstation in order to locate the continuous testing device.

9. A non-transitory computer-readable medium storing instructions executable by a system controller of a clamp monitoring system for verifying the installation of a hose clamp on a working part having a hose and a hose connector, the instructions, when executed, causing the system controller to perform operations including: Receive entry confirmation instructing the working component to enter a pre-determined test package within the workstation; Output a first command prompt to position the continuous testing device at a predetermined target clamp position, wherein the hose clamp attaches and seals the hose to the hose connector of the working component at the predetermined target clamp position; After being positioned at the predetermined target fixture location, a second command prompt is output to activate the continuous testing device; Receive continuity data from the continuity testing device, indicating the continuity status at the hose clamp; Receive position data from the position sensing device indicating the real-time device position of the continuous testing device; as well as In response to the continuity status indicating electrical continuity at the hose clamp and the real-time device position corresponding to the predetermined target clamp position, a notification is output that the hose clamp is correctly installed on the working component.

10. A clamp monitoring system for verifying the installation of a hose clamp on a working part having a hose and a hose connector, the clamp monitoring system comprising: A continuity testing device configured to contact and detect electrical continuity at the hose clamp; A position sensing device configured to detect the position of the continuous test apparatus within a pre-defined test package within a workstation; A system controller, communicatively connected to the continuous testing apparatus and the position sensing device, is programmed to: Receive entry confirmation instructing the working component to enter the predetermined test package within the workstation; In response to receiving the entry confirmation, a first command prompt is output to position the continuity testing device at a predetermined target clamp position, wherein the hose clamp attaches and seals the hose to the hose connector at the predetermined target clamp position; After being positioned at the predetermined target fixture location, a second command prompt is output to activate the continuous testing device; Receive continuity data from the continuity testing device, indicating the continuity status at the hose clamp; Receive position data from the position sensing device that indicates the real-time device position of the continuous testing device; as well as In response to the continuity status indicating electrical continuity at the hose clamp and the real-time device position being aligned with the predetermined target clamp position, a notification is output that the hose clamp is correctly installed on the working component.

Images