Robotic assembly of transport structures using in-situ additive manufacturing

Abstract

Robotic assembly of a transport structure using in-situ additive manufacturing is provided. Techniques for flexible in-situ additive manufacturing of components or portions thereof for a transport structure are disclosed. An automated assembly system for a transport structure may include a plurality of automated constructors to assemble the transport structure. In one aspect, the assembly system may span a complete vertically integrated production process from powder production to recycling. At least some of the automated constructors are capable of moving between stations in an automated manner under the guidance of a control system. A first automated constructor may include a 3‑D printer to print at least a portion of a component and transfer the component to a second one of the automated constructors for installation during assembly of the transport structure. The automated constructors may also be adapted to perform a variety of different tasks utilizing sensors to enable machine learning.

Description

[0001] This application is a divisional application of application number 201810509371.0, filing date May 24, 2018, and entitled “Robotic assembly of transport structures using on-site additive manufacturing”. Technical Field

[0002] The present disclosure relates generally to manufacturing, and more particularly to flexible and automated assembly techniques for manufacturing vehicles, aircraft, boats, and other transportation structures using 3-D printing. Background Art

[0003] Traditional manufacturing facilities may involve significantly inflexible factory infrastructure to produce products in large quantities. For example, a factory may use a fixed robotic assembly system operating on an assembly line to achieve high-volume efficient production. Inflexible factory infrastructure often limits the manufacturing system to only a few models of transportation structures such as vehicles, motorcycles, boats, and airplanes, and even so, each model of the transportation structure may be expensive to tool. If the factory is permanently or long-term configured to produce one or more poorly performing models, the factory may face financial difficulties and operate at a loss due to factory and processing amortization costs. More specifically, due to the inflexibility of the factory, the need to amortize processing before converting factory resources from producing poorly performing products to producing new products or more commercially successful existing products, and other limitations, the factory may be underutilized in these situations.

[0004] Furthermore, where additive manufacturing (AM) techniques may be desirable for three-dimensional (3-D) printing of components or portions thereof for transport structures, such fabricators typically either outsource AM capabilities or, in the case of in-house AM, perform it at a dedicated location away from the assembly line of the transport structure. As a result, these fabricators have little flexibility to modify their AM capabilities to adapt to changes in the environment. Summary of the invention

[0005] Several aspects of systems and methods for 3-D printing of components of transport structures are described more fully below.

[0006] One aspect of an automated assembly system for a transport structure includes a plurality of automated constructors to assemble the transport structure, wherein a first one of the automated constructors includes a three-dimensional (3-D) printer to print at least a portion of an assembly and transfer the assembly to a second one of the automated constructors for installation during assembly of the transport structure.

[0007] One aspect of a method for automated assembly of a transport structure by a plurality of automated constructors, wherein a first of the automated constructors includes a three-dimensional (3-D) printer, comprises: printing at least a portion of components of the transport structure by the 3-D printer; automatically transferring the transport structure from the first of the automated constructors to a second of the automated constructors; and automatically installing the components by the second of the automated constructors during assembly of the transport structure.

[0008] It should be understood that other aspects of the system and method for 3-D printing of components of a transport structure will become apparent to those skilled in the art from the following detailed description, in which only several embodiments are shown and described by way of illustration. As will be appreciated by those skilled in the art, the apparatus and method for manufacturing a transport structure as described herein are capable of other and different embodiments, and that its several details are capable of modification in various other respects, all without departing from the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Various aspects of the flexible and modular robotic fabrication of a transport structure will now be presented in a detailed description by way of example and not by way of limitation in the accompanying drawings, in which:

[0010] Figure 1A A vehicle manufacturing facility including a plurality of robotic assembly stations and a plurality of automated builders is shown.

[0011] Figure 1B A control system of a vehicle manufacturing facility is schematically shown.

[0012] Figure 2 A schematic diagram of a vehicle component production system is shown.

[0013] Figure 3 An alternative linear configuration of a vehicle component production system is shown.

[0014] Figure 4 Examples of additional mounting configurations are shown.

[0015] Figure 5 A schematic diagram of an additive manufacturing assembly system is shown.

[0016] Figure 6 A schematic diagram of the assembly system control system is shown.

[0017] Figure 7 An example of a robotic automation system is shown.

[0018] Figure 8 An example of a structured subassembly is shown.

[0019] Fig. 9An example of a disassembly area is shown.

[0020] Fig.10 An example of a sensor-integrated robotic automation system is shown.

[0021] Fig.11 An example of a component with an integrated label is shown.

[0022] Fig.12 An example of a label is shown.

[0023] Fig.13 A life cycle flow chart of a 3-D printed component with integrated labeling is shown.

[0024] Fig.14A An example of a recognition matrix providing boundary markings is shown.

[0025] Fig. 14B An example of geometric metadata extracted from an identification matrix in an isolation matrix is ​​shown.

[0026] Fig. 14C An example of geometric metadata extracted from an identification matrix on a component part is shown.

[0027] Fig.14D The changes in roll and pitch angles in the identification matrix are shown.

[0028] Fig.15A The solid rectangular portion is shown in a first posture.

[0029] Fig. 15B The solid rectangular portion is shown in a second posture.

[0030] Fig.16 An example of an assembly consisting of six component parts is shown.

[0031] Fig.17 An additively manufactured component with two spatially distributed matrices is shown.

[0032] Fig.18 An arrangement with three spatial distribution matrices is shown.

[0033] Fig.19A A first portion of a flow chart of an exemplary method for automated assembly of a transport structure by an automated builder is shown.

[0034] Fig.19B A second portion of a flow chart of an exemplary method for automated assembly of a transport structure by an automated builder is shown.

[0035] Fig. 20A flow chart of an exemplary method for automated assembly of a transport structure by a plurality of automated constructors, wherein a first of the automated constructors includes a three-dimensional (3-D) printer, is shown.

[0036] Fig.21 A diagram of an exemplary automated laser cutting process is shown.

[0037] Fig. 22 A diagram of an exemplary automated process for assembly of panels having nodes or extrusions is shown.

[0038] Fig.23 A diagram of an exemplary laser cutting process performed at an assembly station is shown.

[0039] Fig.24 A diagram of an exemplary process for adhesive application performed at an assembly station is shown.

[0040] Fig.25 A diagram of an exemplary process for joining and assembling extrusions into a node as performed by multiple collaborative automated constructors is shown.

[0041] Fig.26 A diagram of an exemplary process performed by multiple automated builders for assembling a suspension of a vehicle to a chassis is shown.

[0042] Fig. 27 A diagram of an exemplary process performed by a plurality of automated constructors in lowering a vehicle body onto a chassis is shown. DETAILED DESCRIPTION

[0043] The detailed description set forth below in conjunction with the accompanying drawings is intended to provide a description of various exemplary embodiments for 3-D printing of components for transport structures, and is not intended to represent the only embodiments in which the invention may be practiced. The term "exemplary," as used throughout this disclosure, means "serving as an example, instance, or illustration," and is not necessarily to be construed as being preferred or advantageous over other embodiments presented in this disclosure. In order to provide those skilled in the art with a thorough and complete disclosure that fully conveys the scope of the invention, the detailed description includes specific details. However, the invention may be practiced without these specific details. In some cases, well-known structures and components may be shown in block diagram form, or omitted entirely, in order to avoid obscuring the various concepts presented throughout this disclosure.

[0044] Flexible and modular robotic vehicle manufacturing facilities, systems and methods are needed. The facilities, systems and methods provided herein allow for flexible and modular transport structure manufacturing and assembly. The facilities, systems and methods may include a plurality of variable robotic assembly stations to perform a collection of one or more vehicle manufacturing processes and a plurality of variable robots, such as automated constructors, to perform one or more vehicle manufacturing processes. Flexibility in the manufacture and assembly of vehicles may be provided in the following: 1) variability in the location and / or area of ​​the robotic assembly station; 2) the ability of robots, such as automated constructors, to perform one or more vehicle manufacturing processes with convenient and automated reconfiguration between each process; and 3) customization of vehicle components, including connectors and interconnect materials, by 3-D printing or other techniques. Automated processes allow for the construction and assembly of components, component tracking during assembly and during the life of the component, MAC and flexible construction of various types of vehicles.

[0045] Although reference is generally made to vehicle manufacturing and related facilities for illustrative purposes, it should be understood that the technology described in this disclosure is equally applicable and well suited to other types of transportation structures, including but not limited to boats, airplanes, helicopters, motorcycles, trains, buses, etc.

[0046] Provided herein are flexible and modular vehicle manufacturing facilities, systems and methods for the manufacture and assembly of transport structures. The manufacturing facilities, systems and methods provided herein may be non-design-specific and may be adapted to a wide variety of vehicles and needs. The facility may include one or more robotic assembly stations. Each robotic assembly station may include one or more robots, including an automated constructor. A collection of vehicle manufacturing processes may be performed in each robotic assembly station. The facility may use a combination of 3-D printed parts and commercial off-the-shelf (COTS) parts. Flexibility in the manufacture and assembly of vehicles may be provided in the following: 1) variability in the location and / or area of ​​a robotic assembly station; 2) the ability of a robot, such as an automated constructor, to perform one or more vehicle manufacturing processes with convenient and automated reconfiguration between each process; and / or 3) in-situ printing for easy assembly including connectors and interconnect materials printed by 3-D.

[0047] Increased flexibility and non-design-specific capabilities in manufacturing facilities can provide significant economic advantages. For example, traditional manufacturing systems can establish significantly inflexible factory infrastructure to produce products in large quantities. For automobile manufacturing, scale factories can be used to assemble vehicles. However, even smaller manufacturing plants that do not include stamping facilities and paint shops that do not include stamping manufacturing plants may cost hundreds of millions of dollars to build, equip and maintain. Typically, the resulting manufacturing plants can only support a few vehicle models and / or models, each of which may cost more than $100 million in tools. In order for large inflexible factories that can only build specific vehicles to be profitable, specific vehicles must consume a large portion of the factory capacity. If the factory is inflexibly configured to produce one or more underperforming vehicles, the factory may not be able to replace one or more underperforming vehicles with another vehicle model, because of the costs associated with processing specific models, updating fixtures and programming (e.g., fixed spot welding robots) to assemble traditional body structures. Replacing underperforming models may be economically burdensome before the amortization of the processing is completed.

[0048] Thus, in various exemplary embodiments, the facility may include non-design-specific features to provide flexibility (such as described above and further described below), variability in the location and / or area of ​​the robotic assembly station, the ability of robots such as automated constructors to perform one or more vehicle manufacturing processes with convenient and automated reconfiguration between each process, and / or customization of vehicle components including connectors and interconnect materials through 3-D printing. Unlike traditional batch factories, flexible facilities can be easily reconfigured, such as via an automated system, where machine learning enables robots to reconfigure themselves as needed to produce a variety of vehicles without downtime for reprocessing or reprogramming. In addition, a 3-D printer may be supported on the robotic device, and in some exemplary embodiments, the robotic device may be moved to different assembly stations as needed to 3-D print different parts or components on a dynamic, substantially real-time basis. The printed parts may be further manipulated or moved by supporting the robotic device or by one of any number of automated constructors. For example, the robot may take a 3-D printed part at an assembly station and place the part into a transport structure or insert the printed part into another component for assembly and integration with the component.

[0049] Figure 1AA vehicle manufacturing facility including multiple robotic assembly stations and multiple automated constructors is shown. The vehicle manufacturing facility 1000 may include one or more robotic assembly stations, such as, for example, a first robotic assembly station 1010a, a second robotic assembly station 1010b, a third robotic assembly station 1010c, a fourth robotic assembly station 1010d, etc. The robotic assembly station may include a designated area at a designated location where a collection of one or more vehicle manufacturing processes occurs.

[0050] The vehicle manufacturing process may include any process involved in the manufacture of a vehicle, such as (among many other processes) producing, printing, painting, assembling, disassembling, cutting, bending, stamping, forming, working, machining, processing, smelting, heating, cooling, cleaning, recycling, discarding, painting, inspecting, imaging, and / or testing of vehicle parts, assemblies, and / or accessories of parts or assemblies. One or more types of vehicle manufacturing processes may occur at various stages during vehicle manufacture and / or disassembly.

[0051] For example, while the assembly of a vehicle may include the steps of putting the vehicle together, in the case of a used vehicle being recycled, it may be desirable to disassemble the vehicle. Disassembly may also occur when a chassis or space frame is disassembled to form a chassis with a different profile.

[0052] Although additively manufactured parts can be 3-D printed and thus customized for a specific application, depending on the application, the additively manufactured parts may undergo further steps such as painting, cutting, bending, or other manipulations, for example to accommodate fitting differences or adjust tolerances. In addition, COTS parts or custom parts processed at an assembly plant may involve any of the above steps, including painting, cutting, bending, and stamping, etc. One or more interfaces between parts may undergo heat treatment, and subassemblies may need to be bonded or heat fused. During the recycling process, smelting can be used to extract metal from the material to be atomized into a powder and ultimately used by the additive manufacturing device.

[0053] The components may additionally be cleaned, imaged, inspected and tested for eventual transformation into commercial shipping structures.

[0054] Each of the above steps may be performed in whole or in part by one or more of a plurality of automated constructors at one or more stations. In some exemplary embodiments, each station includes an area designated for specifically performing one of the above tasks, with automated constructors moving to the station or otherwise residing at the station as needed. For example, an automated constructor responsible for inspecting a component may move to a station to perform an inspection. An automated constructor may check the tolerances of a component being assembled to ensure that the component meets one or more specifications. If the component is not within specification, the automated constructor may transmit this information to a central controller or another automated constructor, and the component may be remediated to fall within specification, or if the problem cannot be resolved via available remedial measures, or if the problem is severe in nature, it may be removed from the active assembly.

[0055] In some cases, a vehicle manufacturing process can be independent of other vehicle manufacturing processes. For example, a vehicle manufacturing process can occur independently regardless of other processes that are being performed or have been performed.

[0056] In other cases, vehicle manufacturing processes may depend on other vehicle manufacturing processes. For example, two or more vehicle manufacturing processes may occur simultaneously (e.g., heating and cleaning). In another example, two or more vehicle manufacturing processes may be performed serially and continuously (e.g., cooling after heating). Processes may occur in a specific order (e.g., step A occurs before step B) or may occur serially without regard to order (e.g., step A before step B or step B before step A may both be reasonable). In some cases, two or more vehicle manufacturing processes may occur within a specific time frame. A time frame may be a predetermined period of time.

[0057] One or more vehicle manufacturing processes may be grouped into sets. In some cases, a vehicle may be partially or fully assembled by undergoing one or more sets of one or more vehicle manufacturing processes. For example, a vehicle may be partially or fully assembled by undergoing one or more sets of one or more vehicle manufacturing processes in a particular order. Alternatively, a vehicle may be partially or fully assembled without regard to order. Alternatively or additionally, a vehicle may be intentionally partially or fully disassembled by undergoing one or more sets of one or more vehicle manufacturing processes in a particular order. Alternatively, a vehicle may be partially or fully disassembled without regard to order.

[0058] A set of one or more vehicle manufacturing processes can be performed in each robotic assembly station. Each robotic assembly station can perform a different set of one or more vehicle manufacturing processes. For example, even if one or more manufacturing processes are the same across stations (e.g., a first set of processes that share the same process with a second set of processes), there may be one or more additional manufacturing processes that are different across stations. Alternatively, two or more robotic assembly stations can perform the same set of one or more vehicle manufacturing processes. In some cases, a single vehicle manufacturing process can be performed in one robotic assembly station. Alternatively, multiple vehicle manufacturing processes can be performed in a single robotic assembly station. In some cases, a single vehicle manufacturing process (e.g., smelting) can be performed across two or more robotic assembly stations.

[0059] The vehicle manufacturing facility 1000 may include a single building or multiple buildings. The vehicle manufacturing facility may be integrated into a building that is used to perform one or more additional features. The vehicle manufacturing facility may be or may include one or more manufacturing plants, factories, warehouses, hangers, or any other type of structure. The vehicle manufacturing facility may be or include a campus containing one or more structures. The vehicle manufacturing facility may include one or more roofs and / or one or more walls. Optionally, the vehicle manufacturing facility may appear in an opening without the need for a roof and / or walls. The vehicle manufacturing facility or the structure therein may include one or more vertical horizontal planes (e.g., ground), each of which may be located at, above, or below the ground level. The vehicle manufacturing facility may have an open layout (e.g., without dividers or rooms), or may include one or more rooms or dividers. Any description of the facility herein may be applicable to any combination of structures or layouts as described herein.

[0060] The vehicle manufacturing facility 1000 may include as many robotic assembly stations as possible, or it is desirable to perform one or more collections of vehicle manufacturing processes in the facility. Any description of the robotic assembly station herein may be applied to stations that perform any process described herein, which may include assembly and / or disassembly processes. The vehicle manufacturing facility may include any number of robotic assembly stations. In some cases, the number of stations may be increased or decreased to accommodate the limited capacity and space of the facility. The stations may be distributed over any type of facility structure or layout as described herein. For example, the stations may all be located in the same building, or may be distributed over multiple buildings. These stations may be located within a campus or property that includes one or more buildings. These stations may be located within a portion of a building that may have additional areas dedicated to other functions or activities.

[0061] A station may contain an area of ​​a facility. The areas of multiple stations may or may not overlap. Two or more stations may be adjacent to each other. A station may have a fixed size, location, and / or shape. In some cases, the boundaries of a station may be reinforced by physical objects, such as by dividers, walls, borders, geo-fences, demarcations, or other objects. In some cases, the boundaries of a station may be shown by visual markers such as diagrams (e.g., lines), labels, lighting (e.g., brightness, color, lighting type, etc.), or any other form of markings. Alternatively, the boundaries of a station may not be clearly demarcated by physical and / or visible markers. Alternatively, a station may change size (e.g., increase or decrease), location, shape, or any other characteristics. Such changes may occur over time. Such changes may be provided in response to new or changing needs. For example, in response to increased demand, the size of a robotic assembly station may increase. In addition, the functionality of one or more robotic assembly stations may be changed to meet the increased demand. Similarly, a robotic assembly unit may be reduced in size in response to reduced demand. The functionality of one or more robotic assembly stations may be changed in response to reduced demand. A station may or may not include a work area. The work area may include a platform or area where a vehicle, vehicle parts, and / or vehicle accessories can be placed for operation. For example, an assembly-in-process may be located in a work area within a station area. The work area may be fixed or in motion. For example, the work area may be an autonomous assembly platform. In another example, the work area may be a conveyor belt or other mobile platform. The work area may change in size, position, shape, or other characteristics, such as in response to changes in the composition of the station and / or the function of the station (e.g., a set of processes performed by the station). The work area of ​​the station may be unique to the station (e.g., not overlapping with another station). In some exemplary embodiments, the work area is accessible only to the composition of the station (e.g., a robot associated with the station). The station may include other areas, such as substations (e.g., arm exchange stations, supply stations, etc.) and paths (e.g., robot travel paths, transportation paths for vehicle parts or accessories, etc.).

[0062] Each robotic assembly station may include one or more robots, such as an automated constructor 1020, which is configured to perform a set of one or more vehicle manufacturing processes. An automated constructor may be referred to as a robot, a robotic device, an automated machine, an automated device, an automated device, an automotive tool, or a manufacturing device. An automated constructor may perform assembly or disassembly steps. An automated constructor may perform any manufacturing process as described elsewhere herein alone or in combination with one or more additional automated constructors. For example, an automated constructor may be configured to receive instructions about performing a set of one or more vehicle manufacturing processes, and may also be configured to subsequently execute the received instructions. An automated constructor may have pre-programmed instructions to perform one or more vehicle manufacturing processes. Alternatively or additionally, an automated constructor may receive real-time instructions to perform one or more vehicle manufacturing processes.

[0063] An automated constructor may be able to perform a single vehicle manufacturing process (e.g., bending) in a set of vehicle manufacturing processes. For example, in a robotic assembly station, a first automated constructor may perform a bending process, and a second automated constructor may perform a cutting process. Alternatively, an automated constructor may be able to perform more than one vehicle manufacturing process (e.g., bending, cutting, etc.) in a set of vehicle manufacturing processes. For example, in a robotic assembly station, a first automated constructor may perform both bending and cutting vehicle manufacturing processes, and a second automated constructor may perform both heating and adhesive injection vehicle manufacturing processes. A single automated constructor may perform a single manufacturing process, a single automated constructor may perform multiple manufacturing processes, multiple automated constructors may jointly perform a single manufacturing process, or multiple automated constructors may jointly perform multiple manufacturing processes.

[0064] In some cases, the automated builder may be able to reconfigure to perform different functions. The different functions may be associated with one or more vehicle manufacturing processes that the automated builder is instructed to perform. The reconfiguration may be a hardware reconfiguration or a software reconfiguration. For example, the automated builder may be able to exchange between different robot effectors including different tools required to perform different functions. In another example, the automated builder may be able to reprogram, such as to execute different instructions. In an exemplary embodiment, the automated builder learns new or different tasks, or changes or refinements of existing tasks via machine learning. Machine learning can be autonomous in the following sense: the algorithm that performs the machine learning process is included in a processing system residing in the automated builder, such as one or more processors coupled to a memory or other storage medium. In other embodiments, the processing system in the automated builder communicates with one or more other robots, automated builder, central control system or control facility to guide and prioritize machine learning capabilities. In other exemplary embodiments, machine learning can be independent of certain tasks and can be coordinated. By performing a part on a previous build, the robot can implement a process with expected results on a similar part of a new product. This activity of the robot can include machine learning.

[0065] Machine learning can involve many applications in the context of the manufacture of transport structures. Automated constructors can be programmed with algorithms that, for example, enable them to make predictions based on previously stored data or to make decisions based on previous experience. To this end, machine learning represents a departure from, or more generally a supplement to, the use of static procedures in which automated constructors are programmed to perform one or more tasks without dynamic changes that might otherwise improve the task or make it more efficient.

[0066] One example of machine learning may involve an automated builder whose job may be to use one or more robotic arms or actuators to retrieve a specific component from an automated builder that includes 3-D printing capabilities and then install the component into a transport structure. By way of example, the component may include a transmission component, a gearbox, a heat exchanger, a powertrain, etc., or a sub-assembly of any of the foregoing. Depending on the specific component being installed, the automated builder may, after gaining initial experience installing the component (e.g., initially guided by steps via static program commands), learn one or more ways to more efficiently mobilize itself and position or angle the component for optimal placement in the vehicle.

[0067] These and similar examples of machine learning can help take into account the environment and facilities in which the automated constructor works.

[0068] If the component is also to be fastened to a vehicle, the automated builder can learn in real time through machine learning algorithms the best way to fasten the component, such as attaching screws with other fasteners in a specific order that best or fastest secures the component.

[0069] As another example, machine learning may also involve an automated builder with a goal to modify a COTS part in a certain way using one or more actuators. Although the automated builder in each scenario may modify the COTS part using predetermined specifications to achieve the same end result, the automated builder may employ machine learning to empirically determine the fastest, most effective, and most efficient techniques for performing the modifications, such as by learning to use tools in a specific order or learning through ongoing experience to optimize the modification process by using tools of different sizes.

[0070] Clusters or groups of automated constructors such as robots may also be configured (e.g., using various combinations of algorithms) to work together to achieve faster results on an assembly line, to optimize additive manufacturing by distributing AM work in a more productive manner, or to use different robots for different functions. For example, it may be determined through learning experience by one or more 3-D printing robots that it is more efficient and faster for a group of 3-D printing robots at a station to each print a different subassembly of a gearbox, rather than for each 3-D robot in a group of 3-D robots to work on a different subassembly of a different component (e.g., gearbox, crankshaft, accelerator pedal, suspension, etc.), or vice versa.

[0071] Machine learning among the automation builders can also be used to determine any number of different priorities on a dynamic basis and depending on a set of conditions observed in real time. The robot may recognize that certain tasks require attention from other tasks at certain times, while other tasks may not. For example, a group of automation builders may recognize via machine learning that a given station has become (or will become based on the predictions of the automation builders) a bottleneck. Based on this recognition, more automation builders may change behavior and temporarily transfer to the station in question to resolve the bottleneck.

[0072] As another illustration, machine learning may be as fundamental as one or more automated builders learning new and completely different tasks. A robot originally programmed to weld might then learn to apply adhesives. An automated builder including a 3-D printer may then learn to position or orient itself in an area near a vehicle where its printed parts can be easily passed to another automated builder for faster part placement.

[0073] In another exemplary embodiment, automated builders located at various robotic assembly stations may dynamically employ self-learning techniques to avoid collisions with other automated builders or any other obstacles, including employees working in conjunction with or independently of nearby automated builders at the assembly station.

[0074] Additional examples using machine learning are described below:

[0075] Machine learning for slicing in additive manufacturing . As mentioned above, in one aspect of the present disclosure, an automated constructor may be configured with the ability to perform an additive manufacturing process. In addition to the manufacturing process, slicing refers to the step of cutting (or "slicing") a computer-aided design (CAD) file of a part to be 3-D printed to provide instructions to the printer to print the part. These instructions may include G-Code that provides movement patterns for the print head / deflector to complete the print. Typically, these movement patterns are inefficient and therefore result in slower printing. Machine learning algorithms can be built into the slicing program to provide efficient movement patterns for the print head / precipitator. The algorithm will optimize the path taken by the print head / precipitator to produce faster, higher quality builds.

[0076] Machine learning for printhead motion control . Machine learning can also enable the print head to travel at optimized paths and speeds. Instead of simply moving from point A to point B, a machine learning algorithm can determine the fastest and most efficient path. This optimization process can allow the print head to speed up when printing areas with simple geometry, while slowing down to account for changes in direction. Machine learning can provide greater flexibility to the motion control firmware by optimizing the GCode path to allow for more extreme movements.

[0077] Machine Learning for Materials Development . Machine learning can be used to accurately print parts and / or print on the fly. For example, where a lightweight part is needed, machine learning can guide the automated constructor to print with aluminum. Where a high-strength component is required, the constructor can print with steel. In addition, machine learning can accurately determine the alloy mix as needed, driving alloy development based on load and other considerations (environmental factors, density, vehicle location, etc.).

[0078] Machine Learning for Structural Optimization. During the printing process, machine learning algorithms can automatically generate infill structures in areas that require structural reinforcement. Furthermore, these algorithms can be configured to "panticipate" structures in areas by observing the build phase, and the automated constructor can be instructed to print. Various load cases will be specified before the vehicle is built and will become part of the catalog, providing a database for the machine learning algorithms to reference to print exactly the amount of structure required. Machine learning may potentially be integrated into the CAD design phase itself, where the algorithm would anticipate potential structures and automatically include them. This is similar to the auto-complete algorithms in an internet search bar.

[0079] Machine Learning During Vehicle Assembly In other exemplary embodiments, machine learning algorithms can enable automated builders to obtain the required tools as and when they are needed. For example, during an assembly process where a nut or bolt must be tightened to a specified torque, a builder can recognize this situation and automatically extend the actuator with a torque wrench. Machine learning can also enable these builders to automatically reposition themselves based on the assembly stage, thereby optimizing the factory layout. Tools and parts will be delivered in a timely manner.

[0080] In short, there are potentially very wide variety of applications that may be applicable to the machine learning processes of the present disclosure, depending on the configurations and embodiments discussed. It should be understood that after careful reading of the present disclosure, it is within the grasp of those skilled in the art to design such algorithms that facilitate machine learning (regardless of their source, such as the automated constructor itself or a central control location that is subsequently sent to the automated constructor). Common and non-exhaustive examples of potentially applicable machine learning algorithms can include decision tree learning algorithms, linear and logistic regression, classifier and support vector machine algorithms, etc. From more common algorithms such as the above, those skilled in the art can develop more complex algorithms or groups of algorithms that combine logic, experience, and prediction with motion and action.

[0081] In addition to algorithms, the automation constructor can also use multiple machine learning sensors to collect data related to the machine learning process and perform other functions. For example, the automation constructor can be equipped with low-power sensor nodes that are configured to collect various types of data that can be used in machine learning applications. The collected data can be sent to a processing system in the automation constructor or, for example, sent to a central control facility via a wireless connection for further processing and / or routing to other automation constructors. Sensors can include, for example, optical sensors, thermal sensors for detecting temperature, sensors for detecting the presence of charge or voltage, acoustic sensors, and sensors for detecting chemicals (including potentially harmful chemicals to vehicles, nearby components, the environment, or other) adjacent to the automation constructor. Sensors can also include RF sensors, radio sensors, and other electrical sensors for receiving radio signals or messages.

[0082] The automation constructor can be configured to travel to and from the robot assembly station and in the robot assembly station. The robot assembly station can include as many automation constructors as required for executing a set of one or more vehicle manufacturing processes associated with the robot assembly station. For example, depending on the embodiment, the robot assembly station can include anywhere from 1 to 1000 automation constructors or more. In other embodiments, each robot assembly station can have any number of automation constructors. For example, they may or may not have the same number or type of automation constructors. The number and / or type of automation constructors in each robot station can be selected independently of other robot stations. The automation constructor can be associated with one or more robot assembly stations. For example, the automation constructor can be associated only with the first robot assembly station 1010a. In another example, the automation constructor can be associated with both the first robot assembly station 1010a and the second robot assembly station 1010b. In some cases, when the automation constructor is located in the area of ​​the robot assembly station and / or the automation constructor is performing a manufacturing process associated with the robot assembly station, the automation constructor can be associated with one or more robot assembly stations. For example, if a robotic assembly station is associated with a portion of an assembly chassis, an automated constructor can assist in assembling a portion of the chassis. The association of an automated constructor may change depending on demand. For example, if there is a greater demand for an automated constructor in a first robotic assembly station, the automated constructor may be associated with the first robotic assembly station. When the demand for the second robotic assembly station increases and the demand for the first robotic assembly station decreases, the automated constructor may become associated with the second assembly station. An automated constructor can only be associated with one workstation at a time. Alternatively, it may be associated with multiple stations at a time. In some cases, an automated constructor may not be associated with any station at a particular moment. For example, one or more "extra" automated constructors may be idle or waiting until they are associated with a robotic assembly workstation. For example, an automated constructor 1020 may be idle unless and until instructions are provided to it, for example, from a control system or another automated constructor 1020 to mobilize to a robotic assembly station and perform assigned tasks.

[0083] In some cases, an automated constructor may move through various areas of a manufacturing facility as needed. Figure 1AAs shown in FIG. 1 , the automated constructor 1020 can travel from the first robotic assembly station 1010a to the second robotic assembly station 1010b. When in the first robotic assembly station, the automated constructor can perform a manufacturing process associated with the first robotic assembly station. When the automated constructor travels to the second robotic assembly station, the automated constructor can perform a manufacturing process associated with the second robotic assembly station. In some cases, the automated constructor 1020 can leave the robotic assembly station 1010b. This may occur when the automated constructor is no longer needed at the robotic assembly station, or if a larger one is needed at a different location. In some cases, the automated constructor 1020 can enter the robotic assembly station 1010c. This may occur when the automated constructor is needed at the robotic assembly station. The automated constructor can travel within the robotic assembly station 1010d.

[0084] In some cases, the designated area and / or designated position of the robotic assembly station can change with the corresponding position and movement of one or more automated constructors in the assembly station that performs the set of one or more vehicle manufacturing processes. For example, if one or more automated constructors associated with the first robotic assembly station 1010a travel to the position of the second robotic assembly station 1010b, and one or more automated constructors associated with the second robotic assembly station travel to the position of the fourth robotic assembly station 1010d, the position of the first robotic assembly station can be changed to the initial position of the second robotic assembly station, and the position of the second robotic assembly station can be changed to the initial position of the fourth robotic assembly station. Two or more robotic assembly stations may share the same designated position. Two or more robotic assembly workstations may partially or completely overlap in the designated area. In other cases, the designated area and / or designated position of the assembly station may change with the corresponding size and / or position of the components or accessories of the components of the vehicle that are the subject of the set of one or more vehicle manufacturing processes.

[0085] The vehicle manufacturing facility may include a vehicle transport system that can transport vehicles or other transport structures or parts of transport structures to multiple locations (e.g., robot assembly stations, etc.) during the assembly process. For example, the transport system may include a mobile platform, such as a conveyor belt. In some cases, a gantry may be used to transport vehicles or parts. Alternatively or additionally, the transport system may include one or more robots (e.g., mobile supply vehicles) that are programmed to transport partially or completely assembled vehicles or other transport structures undergoing an assembly process, or vehicle parts. Alternatively or additionally, the transport system may include, for example, manual labor from a facility employee who has instructions to transport vehicles or vehicle parts to multiple locations in the facility. For example, the vehicle transport system may be a combination of conveyor belts, robots, and / or manual labor (e.g., an employee provides a tube to a mobile supply vehicle at location A, the mobile supply vehicle transports the tube from location A to a conveyor belt at location B, and the conveyor belt transports the tube from location B to multiple other locations in the facility). The transport system may transport the vehicle or vehicle parts to different locations within the same robotic assembly station, between different robotic assembly stations, and / or between a robotic assembly station and another location.

[0086] In some cases, during the vehicle assembly process, multiple types of transport structures (e.g., a first aircraft, a second aircraft, a first motorcycle, a second motorcycle, a first car model, a second car model, a first boat model, a second boat model, a first bus model, a second bus model, etc.) can be transported to one or more robotic assembly stations via the vehicle transport system. Alternatively or additionally, multiple types of vehicle components (e.g., wheels, tubes, engines, etc.) or accessories of vehicle components can be transported to one or more robotic assembly stations via the vehicle transport system. The facility can assemble and / or disassemble multiple vehicles simultaneously.

[0087] The facility can assemble and / or disassemble multiple types or models of transport structures simultaneously. For example, in the case of vehicles, a first vehicle model can pass through various robotic assembly stations in the facility, each station being located at a different location in the facility for different stages of its assembly. At the same time, in parallel, a second vehicle model can pass through various different robotic assembly stations in the facility for different stages of its assembly. The first and second vehicle models can pass through the same and / or different robotic assembly stations. Optionally, the first and second vehicle models can pass through the same robotic assembly station at the same time or at different times. The facility can support the simultaneous assembly and / or disassembly of any number of vehicles or vehicle models. The differences (e.g., designs) of the vehicle models assembled and / or disassembled simultaneously may vary dramatically (e.g., building a boat, a car, and a bus at the same time) or narrowly (e.g., building three different series of models of the same car brand, each series including the same body design).

[0088] One or more robotic assembly stations can be reconfigured to support the assembly and / or disassembly of different vehicle models. In some cases, transport structures of various models can be assembled and / or disassembled in batches. For example, one or more robotic assembly stations can be configured to assemble a first vehicle model. After assembling the first vehicle model of the first batch, one or more robotic assembly stations can be reconfigured to assemble the second vehicle model of the second batch. Alternatively or additionally, the robotic assembly station can be reconfigured as needed (e.g., configured to build one of the first vehicle model, then reconfigured to build one of the second vehicle model, then reconfigured to build one of the third vehicle model, then reconfigured back to build one of the first vehicle model, etc.). Therefore, when different vehicle models or types are assembled in series, the robotic assembly station can be reconfigured as needed. As described above, different vehicle models can arrive in large batches, or can be individualized so that each vehicle can be a different model, or anywhere in between. The number of vehicles in a series of the same vehicle model or type may vary based on demand. For example, a robotic assembly station might be used to build a large batch of 1,000 vehicles of the same type, then the robotic assembly station might be used (which might optionally need to be reconfigured to accommodate a different vehicle type) to build several vehicles of another type, and then a medium-sized batch of a hundred or so vehicles of another type might be built using the robotic assembly station (which might optionally need to be reconfigured again to accommodate a third vehicle type).

[0089] The respective functions and / or movements of the one or more automated constructors may be controlled by a control system. Figure 1BThe control system of a vehicle manufacturing facility is schematically shown. The control system 1500 may include a control server 1505. As used herein, a server may generally refer to a computer that provides services (e.g., sending and receiving instructions) or resources (e.g., data) through a network connection. The server may be provided or managed by an administrator (e.g., a factory manager) of a vehicle manufacturing facility. In some cases, the server may include a network server, an enterprise server, or any other type of computer server, and may be computer-programmed to accept requests (e.g., HTTP or other protocols that may initiate data transmission) from a computer device (e.g., a robot, an automated constructor, a 3-D printer, etc.) and provide the requested data to the computing device. In addition, the server may be a broadcast facility for distributing data, such as free broadcasting, cable television, satellite, and other broadcast facilities. The server may also be a server in a data network (e.g., a cloud computing network). Any description of the server here may be applied to one or more servers or other devices that may independently or jointly perform any steps described elsewhere herein. Alternatively or additionally, the system may be implemented using a cloud computing infrastructure or a peer-to-peer configuration. In some exemplary embodiments, the server may reside locally within the assembly facility, or it may reside on its campus or building, or be networked to one or more dedicated locations at the assembly facility.

[0090] The control server 1505 may include known computing components, such as one or more processors, one or more memory devices storing software instructions executed by the one or more processors and data. The server may have one or more processors and at least one memory for storing program instructions. The one or more processors may be a single microprocessor or multiple microprocessors, a field programmable gate array (FPGA), a digital signal processor (DSP), or any suitable combination of these or other components capable of executing a particular instruction set. Computer-readable instructions may be stored on a tangible, non-transitory computer-readable medium, such as a floppy disk, a hard disk, a CD-ROM (Compact Disc Read Only Memory), an MO (Magneto-Optical), a DVD-ROM (Digital Versatile Disk Read Only Memory), a DVD RAM (Digital Versatile Disk - Random Access Memory), or a semiconductor memory. Alternatively, the methods disclosed herein may be implemented using hardware components or a combination of hardware and software, such as, for example, an ASIC (Application Specific Integrated Circuit), a special-purpose computer, or a general-purpose computer. Although Figure 1B The control server is shown as a single device 1505, but in some embodiments, multiple devices (e.g., computers) may implement the functionality associated with the control server. The one or more processors may further be capable of using cloud storage and any future memory or storage capabilities to be implemented in the future, including but not limited to storage capabilities that may be necessary to implement the Internet of Things (IoT).

[0091] The network 1515 can be configured to connect and / or provide communication between various components (e.g., one or more automated builders 1520a-x, other robots, 3-D printers, other machines, sensors, etc.) and the controller system 1500. For example, the network can be implemented as the Internet, an intranet, an extranet, a wireless network, a wired network, a local area network (LAN), a wide area network (WAN), Bluetooth, near field communication (NFC), a wireless network, ... Figure 1B Any other type of network that enables communication between one or more components of the network layout in the embodiment of the present invention, or any combination of the networks listed above. In some embodiments, the network can be implemented using a cell and / or paging network, satellite, licensed radio, or a combination of licensed and unlicensed radio. The network can be wireless, wired (e.g., Ethernet), or a combination thereof.

[0092] The control system 1500 may be implemented as one or more computers storing instructions that, when executed by one or more processors, may generate instructions and send the instructions to one or more automation constructors 1520a-x and receive data and / or instruction requests from one or more automation constructors. The facility 1000 may include one or more control systems, each of which operates substantially in parallel and / or in conjunction with the control system 1500. In some cases, a control server may include a computer in which one or more control systems are implemented. Alternatively, one or more control systems may be implemented on separate computers. The control server may access and execute one or more control systems to perform one or more processes consistent with the disclosed embodiments. In some configurations, one or more control systems may include software stored in a memory accessible by the control server (e.g., a memory local to the control server or a remote memory accessible via a communication link such as a network). Therefore, in some aspects, one or more control systems may be implemented as one or more computers, as software stored on a memory device accessible by the control server, or a combination thereof. For example, one control system may be computer hardware, and another control system may be software that can be executed by the control server.

[0093] One or more control systems may be used to control various components of the vehicle manufacturing facility 1000 in a variety of different ways, such as by storing and / or executing software that executes one or more algorithms to implement control. Although multiple control systems for executing one or more algorithms have been described, it should be noted that a single control system may be used to execute some or all of the algorithms consistent with the disclosed embodiments.

[0094] One or more control systems may be connected or interconnected to one or more databases 1510. One or more databases 1510 may be one or more memory devices configured to store data (e.g., sensor data, component manufacturing data, inventory data, etc.). In addition, in some exemplary embodiments, one or more databases may be implemented as a computer system with a storage device. In one aspect, the control server 1505 may use one or more databases to perform one or more operations consistent with the disclosed embodiments. In certain embodiments, one or more databases may be co-located with the control server and / or co-located with other components (e.g., automation constructors 1520a-x) on the network 1515. For example, the automation constructor 1520 may send sensor data to one or more databases without passing through the control server. Those of ordinary skill will recognize that the disclosed embodiments are not limited to the configuration and / or arrangement of one or more databases.

[0095] The control system 1500 can be configured to generate instructions for one or more automated constructors 1520a-x to travel to and from each assembly station. For example, the control system can instruct one or more automated constructors to autonomously travel to and from each assembly station. The automated constructors may have different levels of autonomous independence. For example, the control system can allow the automated constructor to travel on its own without providing any instructions. For example, the automated constructor may have pre-programmed instructions to travel on its own, such as via communication with the control system and / or communication with other automated constructors. In another example, the automated constructor may have pre-programmed conditions or parameters that the automated constructor must comply with when traveling on its own. In some cases, the control system can provide periodic or continuous updates to the software in the automated constructor, such as redefining pre-programmed conditions or parameters, updating learning capabilities (e.g., capabilities for autonomous travel) or assigning new or different tasks. Alternatively or additionally, the control system can provide more detailed (e.g., step-by-step) instructions to one or more automated constructors to travel to and from each assembly station. For example, the control system can provide a specific travel path for the automated constructor. In another example, the control system can provide a target destination, and the automation constructor can be programmed to reach the target destination by following any path. The automation constructor can follow one or more parameters when determining the path, or can freely determine the path on the fly. In another example, the control system can provide a target destination and parameters, such as allowed paths and prohibited paths, allowed areas and prohibited areas in the facility, preferred paths, preferred areas, and / or time limits. The automation constructor can reach the target destination within the provided parameters. The instructions can be pre-programmed in the automation constructor or provided as real-time instructions. Without any pre-planning of the path, the automation constructor can optionally operate autonomously when traveling along the path. The constructor can generate the path in real time.

[0096] The automated builder may also employ machine learning techniques as described in the present disclosure to increase its ability or effectiveness to autonomously travel, for example, between assembly stations. For example, the automated builder may use one or more sensors to identify stationary or moving obstacles, and may record information or parameters about any of these obstacles, which may help the automated builder develop future paths of travel or avoid collisions. In some cases, the automated builder may transmit this machine-learned information to the control system 1500, depending on factors such as the degree of autonomy of the automated builder, as governed by its software or hardware capabilities, pre-transmitted instructions from the control system 1500, or otherwise.

[0097] In some cases, the control system 1500 can change the designated position and / or designated area of ​​the robotic assembly station, such as by indicating the movement of one or more automated constructors associated with the robotic assembly station. In this way, the robotic assembly station can be flexible and modular, and the vehicle manufacturing facility 1000 can be easily reconfigured by changing the corresponding position and / or area of ​​each robotic assembly station within the limitations of the facility location and / or facility area. In some cases, the facility may include one or more parts of a building, and in some cases, the facility may include one or more different buildings. As limited by the location and / or area of ​​the facility, one or more robotic assembly stations can be distributed in any layout. For example, a first robotic assembly station may be located at a first building of a facility, and a second robotic assembly station may be located at a second building of a facility.

[0098] In some exemplary embodiments, the control system 1500 can generate instructions in real time. Some examples of real-time activities can include response times of less than 1 second, one tenth of a second, one hundredth of a second, or a millisecond. Each robot including one or more automated constructors, such as those further described above or below, can respond to instructions from the control system in real time or near real time in these embodiments. For example, by the movement of one or more automated constructors, the robot assembly station can be reconfigured and scaled in real time or near real time in a position and / or region. In some cases, the control system can generate periodic instructions. Periodic instructions can be regular, such as according to a schedule or regular intervals (e.g., every 10 minutes, every hour, every day, every week, etc.) or irregular. Instructions can be provided according to a predetermined schedule. Instructions can be provided in response to detected events (e.g., initiating the assembly of a new transport structure, exhaustion of raw material supply, one or more machine failures, etc.).

[0099] The control system 1500 can be further configured to generate instructions for one or more automated constructors to perform a manufacturing process for a transport structure. In the case of a vehicle, the control system 1500 can be configured to generate and / or provide instructions for one or more automated constructors to perform one or more vehicle manufacturing processes or one or more sets of one or more vehicle manufacturing processes. For example, the control system 1500 can completely change the set of one or more vehicle manufacturing processes associated with a robotic assembly station. The control system can give detailed instructions about performing a vehicle manufacturing process to one or more automated constructors. For example, the control system can give specific dimensions of a vehicle component to a 3-D printing automated constructor for printing. A more detailed description of one or more automated constructors that perform one or more vehicle manufacturing processes is further provided below.

[0100] Figure 2A schematic diagram of a component production system for a transport structure is shown. Although the details and concepts may be applied to any suitable transport structure as described above, this is shown in the context of an exemplary vehicle component production system. Figure 2 . The vehicle manufacturing facility 2000 may use vehicle components produced on-site or off-site at the facility. Some vehicle components may be initially produced off-site and, if necessary, may be altered or processed on-site. Alternatively, some vehicle components may be initially produced on-site and altered or processed off-site. In some cases, on-site component production may include three-dimensional (3-D) printing. In some cases, off-site components may include commercial off-the-shelf (COTS) components. COTS components may also be 3-D printed. In some cases, existing components (e.g., 3-D printing, COTS, etc.) may be customized via 3-D printing. As used herein, the terms "component" or "vehicle component" may collectively refer to a component to be assembled in a vehicle or other transport structure and one or more manufacturing tools capable of interacting with or manipulating the component to be assembled.

[0101] In an exemplary embodiment involving a vehicle assembly facility, vehicle parts can be produced on-site by 3-D printing. Old vehicles and transport structures and old vehicle parts can be input into the vehicle part production system for disassembly in the disassembly area 2100. Old vehicles and old vehicle parts can be native to the system (e.g., manufactured and / or assembled by the same facility 2000) or external to the system (e.g., manufactured and / or assembled by different facilities). The disassembled components of old vehicles and old vehicle parts can be reused, recycled or discarded in the metal recovery area 2110. For example, metal parts can be recycled. Metal recycling parts and other printed structural supports can be conveyed to the smelter in the metal recovery area 2110 to produce ingots. Ingots can be produced from metals from any source, including sources other than disassembled old transport structures including vehicles and old vehicle parts. Other disassembled parts that cannot be reused or recycled may be discarded from the system. Ingots can be fed into the powder production crucible tower 2120, where they can be converted into metal powders, such as by undergoing gas atomization or another suitable process for converting recycled ingots into metal powders. The metal powder output from the powder production crucible tower can be fed to one or more 3-D printers in the component production area 2130, and in some embodiments as described below, the output powder can be transported directly to one or more 3-D printing robots on the assembly line. The 3-D printer can use metal powder from other sources, such as commercially available metal powder. It will be understood that the 3-D printer is not limited to using metal powder as a base material for rendering 3-D objects, and plastics, composite materials and other materials can be transported to the component production area and / or directly to the 3-D printing robot and used as material for 3-D printing one or more components or parts thereof.

[0102] The part production area 2130 may include an enterprise resource planning (ERP) system that can direct one or more 3-D printers to produce vehicle parts or complete COTS or other parts. In an exemplary embodiment, the ERP system may include a system that enables the facility 2000 to use integrated software applications to manage and automate many functions and manufacturing processes. For example, the ERP system may instruct one or more 3-D printers to include necessary details or modifications in the printed vehicle parts. The ERP system may include software that automates and integrates core business processes (such as manufacturing processes) by leveraging large and small data (such as customer orders, manufacturing target objectives, inventory records, parts databases, financial data, and manufacturing schedules). In some cases, Figure 1BThe control system 1500 may include an ERP system in its software. Alternatively, the ERP system may be a system separate from the control system. In some cases, the 3-D printer may include a fixed machine. Alternatively or additionally, the 3-D printer may include a 3-D printing robot. The 3-D printing robot may be capable of traveling and configured for traveling. The 3-D printing robot may be performed on an assembly line. In some cases, the 3-D printing robot may be an automated constructor associated with one or more robotic assembly stations.

[0103] Fig. 20 An illustrative block diagram of an exemplary method for on-site 3-D printing of components at a robotic assembly station is shown. In the exemplary method, as shown in 2001, a control system can provide instructions to or communicate with one or more automated constructors involved in the 3-D printing process. Alternatively, the automated constructors operate in an autonomous or semi-autonomous manner.

[0104] In some embodiments, the material for 3-D printing may include powders obtained from recycled metals, as shown in step 2005 and described above. In other exemplary embodiments, the 3-D printing material may include plastics or composite materials and may be obtained from any suitable source. At step 2010, a first automated constructor including a 3-D printer 3-D prints a component or a portion thereof. That is, in some embodiments, the 3-D printer is constructed as an integral part of the first automated instructor. In other embodiments, a separate 3-D printer is supported by the automated constructor, such as on a platform or through the use of one or more arms or actuators, etc. In an exemplary embodiment, the first automated constructor is capable of moving to and from different robotic assembly stations in an automated manner as needed, such as following real-time instructions from a control system.

[0105] As described in step 2010, 3-D printing of a portion of a component can mean, for example, that a first automated constructor 3-D prints a portion of a component onto an unprinted second portion of a component, such as, for example, a COTS component. Alternatively, the first automated constructor can work in conjunction with another automated constructor that also includes a 3-D printer, and each automated constructor can contribute to 3-D printing a portion of a component. As another example, the first automated constructor can 3-D print a portion of a component in whole or in part onto a second portion of a component that was previously 3-D printed.

[0106] In an exemplary embodiment, as shown in step 2014, a first automated printer may print an interconnect configured to interconnect a component to another structure.

[0107] Thus, in step 2020, the component can be transferred from a first automated builder having a 3-D printer to a second automated builder in an automated manner. In an exemplary embodiment, the first automated builder uses one or more arms and / or actuators at the distal end of the arm to transfer the 3-D printed component (or a portion thereof) to the second automated builder, the function of which can be to move the component to a nearby location for installation and / or release the first automated builder so that it can perform other printing tasks. In another exemplary embodiment, the second automated builder uses a robotic arm and / or actuator to grab or engage the 3-D printed component and take it away from the first automated builder. In other embodiments, more than one automated builder can be used to perform this task. During these processes, as shown in step 2025, one or more of the first or second automated builder can exchange robotic arms and / or actuators to obtain those necessary to perform the necessary manipulations using the 3-D printed component.

[0108] Thus, the second automated builder (either by itself or with the aid of another machine, robot, or automated builder) installs the component in an automated manner in the appropriate location during assembly of the transport structure, as shown in step 2030. For example, the second automated builder may use its capabilities to position the component in the transport structure for installation therein.

[0109] The component production processes described above and the processes described further below can be clearly performed in one or more robotic assembly stations. For example, disassembly may occur in a first robotic assembly station (e.g., robotic assembly station 1010a in Figure 1), smelting of the disassembled components into ingots may occur in a second robotic assembly station, gas atomization of the ingots into metal powder may occur in a third robotic assembly station, and 3-D printing may occur in a fourth robotic assembly station. Alternatively, one process (e.g., 3-D printing) may occur in more than one robotic assembly station (e.g., 3 stations). Alternatively, more than one (e.g., disassembly and smelting) process may occur in the same robotic assembly station.

[0110] While the 3-D printed parts are printed by one or more 3-D printers, such as 3-D printing robots, the 3-D printed parts can be machined simultaneously in a suitable position (such as on an assembly line). Alternatively, the 3-D printed parts can be post-printed in a subsequent automated stage in a post-printing processing system. The post-printing processing system may include one or more computer numerical control (CNC) machines, which can be configured to perform automated and repeatable surface treatment of 3-D printed parts. For example, the CNC machine may include a head for shot peening to enable automated and repeatable surface treatment. Shot peening is a process of shaping metals or composite materials by bombarding them with metal jets. The 3-D printed parts can be further painted, cut and / or bent. For example, the system may include a paint sprayer for painting, a bending machine for bending, and a cutting machine (e.g., laser, water jet) for cutting or trimming. The post-printing processing system can be configured to hold and constrain a substrate or other additional elements (e.g., attachment points) of the 3-D printed parts to be processed to fix the parts during processing.

[0111] In some cases, 3-D printed parts, such as powders or other unwanted materials (e.g., particles), may be cleaned prior to undergoing a separate machining step (e.g., surface treatment). For example, the 3-D printed parts may be conveyed to an automated cleaning station (e.g., in a separate robotic assembly station) to remove powder or other unwanted particles from the parts. The automated cleaning station may include a shaking system, a vacuum system, a combination of shaking and vacuum systems, or other techniques for removing material from the printed parts. The post-printing processing system may further include an oven for thermal treatment of the 3-D printed parts. In some cases, heating and cleaning may be performed simultaneously on the printed parts. The heat profile for the thermal treatment process may be determined and controlled by a control system (e.g., a main control system, an ERP system, etc.) that includes information on the required processing and finishing processes for the printed parts. Again, refer to Figure 2 Once the printed parts have been processed, the printed parts can be transferred to various subsystem build lines 2400, such as the chassis build line 2300.

[0112] 3-D printing technology for component production can provide flexibility in many ways. For example, different parts can be printed as needed. This can advantageously reduce the time to obtain components (e.g., transportation and delivery from another source), reduce inventory space (e.g., storage of components that can be used later), and increase supervision of accuracy and precision during printing. In addition, there is considerable freedom in the customization of components, limited only by the increasing restrictions that 3-D printers can print. This can advantageously accommodate the assembly or disassembly of different vehicle models without having to change infrastructure or make other long-term changes to facilities. In addition, the 3-D printer can be supported on a robotic device and can be moved to different assembly stations as needed. In an exemplary embodiment, the control system 1500 can generate instructions provided to the robotic device to enable it to move autonomously to another assembly station or other location. In other exemplary embodiments, the 3-D printer can be moved to another assembly station by or with the aid of one or more additional automated constructors or mobile supply vehicles.

[0113] On the other hand, the vehicle manufacturing facility 2000 can use commercial off-the-shelf (COTS) components. COTS components can include standard COTS components for assembly and structural COTS components for building complex structures (e.g., chassis). COTS components can be produced on-site, such as in the COTS production subsystem 2800, or they can be obtained from off-site sources. For example, COTS components that require some form of customization can be manufactured on-site. Alternatively, 3-D printing technology or standard machining technology can be used to customize or change existing COTS components. In some cases, COTS components can be both standard COTS components and structural COTS components. Structural COTS components can be used when received. Alternatively or additionally, structural COTS components can be adjusted or customized (e.g., via processing) for use in complex structures. Structural COTS components can be obtained at low cost based on the large volume (e.g., batch) of their corresponding production systems. In some exceptional cases, structural COTS components may require little or no processing and can be incorporated into accessories or complex structures with little or no processing amortization. For example, a structural COTS component may include honeycomb or other structural panels including materials such as carbon fiber, fiberglass, and aluminum, which may also optionally contain a foam core. Structural COTS components may also include tubes that may have any cross-section, which may include materials such as carbon fiber, aluminum, titanium, fiberglass, plastic, steel, and any combination of the above or other materials. Structural COTS components may also include extrusions. Extrusions may require minor machining, such as for modifying or fixing cross-sections. Extrusion molds may be saved for subsequent transport structure fabrication. In some cases, a catalog of all tools and fixtures made or received may be stored in a component production system database, which in some embodiments may be included in database 1510( Figure 1B ). A vehicle optimization system (e.g., ERP system, control system) can access a component production system database to coordinate and optimize the vehicle manufacturing process. For example, a vehicle optimization system can prevent redundant purchases or manufacturing of existing tools (e.g., extrusion dies).

[0114] COTS parts may optionally be received at the COTS parts and receiving area 2209. Once the COTS parts are received by the system at area 2200, or alternatively mass-produced on site (e.g., at the COTS production area 2800), they may be transferred to the bending area 2210 and / or the cutting area 2220. COTS parts may be bent or cut in any order, such as is efficient and / or feasible for the desired part design. For example, the COTS parts may first be transferred to the bending area, and then to the cutting area. Alternatively, the COTS parts may first be transferred to the cutting area, and then to the bending area. Alternatively, the COTS parts may first be transferred to the cutting area, and then to the bending area, and then returned to the cutting area. In some cases, the cutting area and the bending area may each include a robotic assembly station. The bending area may include an automated bending machine configured to bend the COTS parts into a desired shape. The bending may be done on multiple axes. The cutting area may include a laser and water jet system configured to trim the COTS parts. COTS parts can be trimmed in three dimensions. Any location on a COTS part can be trimmed, including locations other than the endpoints. For example, at a cutting area, an extrusion can be shortened to the correct length with the desired fillet at one end, and a portion of its cross section in the middle, where shear loads are less significant in a particular design, can be reduced for clearance and weight savings. In some cases, such as when a bend or cut needs to be completed in a vehicle location, trimming and / or bending can be performed on the assembly line.

[0115] In addition to structural COTS components, facility 2000 may also use standard COTS components that may be used as part of a final product assembly. For example, standard COTS components may include a transmission, a bogie, and a tire. Standard COTS components may be used as received in an assembly. For example, a standard COTS component such as a tire may be purchased and may be directly installed on a wheel without modification. Alternatively or additionally, standard COTS components may be adjusted or modified prior to incorporation. For example, a standard transmission COTS component provided to the COTS component receiving area 2209 by a major automotive transmission layer 1 manufacturer may be moved to the laser cutting area 2220 where existing fixing points are cut off. Fig.21and then moves to component production area 2130 where new fixation points are printed thereon by a 3-D printing enabled robot. Alternatively, a 3-D printing enabled robot (e.g., an automated constructor supporting a 3-D printer or having 3-D printing capabilities) may print on new fixation points on the assembly line. It may be noted that because the transmission may be a stress bearing member in certain transport structures, the transmission may be considered both a standard COTS component and a structural COTS component. In some cases, tire tooling may be printed, such as in component production area 2130 or COTS production area 2800, to advantageously enable high speed production of tires with low tooling costs.

[0116] Once the COTS parts have been processed (e.g., bent, cut, printed, etc.), they can be transferred to various subsystem build lines 2400 (e.g., suspension, powertrain, chassis, interior, etc.) including the chassis build line 2300 and 3-D printed parts. For example, the chassis build line may include three robotic assembly stations, including a first station 2310 for dry build, a second station 2320 for bonding, and a third station 2330 for component build. The chassis build line may perform such functions as inspection (e.g., scanning), adhesive injection, bolting, placement or deposition, 3-D printing of components, imaging (e.g., via a camera), and movement (e.g., via a conveyor) of components. Each of the other subsystems 2400 may include one or more robotic assembly stations. The final product in each subsystem (e.g., vehicle suspension, powertrain, chassis, aircraft fuselage, etc.) may be assembled during final assembly 2500.

[0117] In addition to 3-D printed structural parts and standard and structural COTS parts, the part production system can further include additional and independent inputs. For example, in the body production area 2700, the system can produce customized exterior body panels and other custom molded components. The body panels can include materials such as aluminum, carbon fiber, fiber reinforced plastic, or plastic. Beneficially, the production of body panels and other custom molded components on-site at the facility 2000 can reduce processing costs because it does not require expensive processing and stamping capital equipment used for traditional steel bodies.

[0118] The use of plastic, carbon and / or aluminum bodies may allow the body to be wrapped rather than painted, advantageously reducing environmental contamination of the facility 2000 that may be caused by painting. Wrapping of the body panels may be performed at the end of the body panel production area.

[0119] The body production area 2700 can also produce other custom-molded body parts. For example, the body production area can produce low-profile custom roof rails made of carbon fiber to reduce mass and be formed to be consistent with or even joined to the outer body of the vehicle. Custom-molded body parts can be produced via traditional layup or autoclave processes. Alternatively, custom-molded body parts can be made with 3-D printed tools, which can advantageously reduce capital expenditure costs. The costs associated with the tools used to manufacture parts may not need to be amortized across a large number of vehicles. For example, if the corresponding parts (e.g., custom roof rails) manufactured using the tool are expected to be used in other vehicles in the manufacturing facility 2000 in the future, or for other products, the low-cost 3-D printing tool can be reused. Alternatively, if the system (e.g., vehicle optimization system, ERP system, control system) determines that the possibility that the tool will be reused is low, the tool can be recycled, such as by disassembling at area 2100 and recycling in recycling area 2110.

[0120] Once all production inputs (such as 3-D printed parts, standard and structural COTS parts, body parts, other tools and / or materials) are delivered to the appropriate locations on the assembly line via a transportation system, vehicle assembly can begin. The assembly line may include a conveyor belt, gantry arrangement, or other form, and may transport parts from one location to locations online or offline, where processes are performed at each location. Alternatively, the assembly line may include a fixed work area where all processing is performed at substantially the same location. For example, as previously described, the transportation system may include robots or manual labor to transport parts to the work area, and different processing may be performed by, for example, enabling the robot to move relative to the work area. The assembly line may end 2900 after the final assembly 2500 and the body assembly 2600, 2650 are completed. The assembly method in the assembly line is described in further detail below. Although the present invention has been described with reference to FIG. Figure 2 Although various systems and processes (e.g., disassembly, smelting, powder production, laser and water cutting, CNC bending, cleaning stations, ovens, etc.) are described in connection with the component production system in FIG, a person of ordinary skill in the art will recognize that assembly facilities for different types of transportation structures (such as aircraft, boats, motorcycles, snowmobiles, and public transportation structures, etc.) may include additional or different areas, systems, and subsystems, such as those described above with respect to vehicle manufacturing facilities. Furthermore, it will be understood that a vehicle manufacturing facility need not include all of the various systems and processes described above, and that the various systems and processes need not be as described above. Figure 2Alternatively or additionally, a vehicle manufacturing facility may implement variations of the various systems and processes described. For example, a facility may include only a sample of the process, such as using only COTS parts instead of 3-D printed parts, or vice versa. For example, as previously described, a COTS part may be trimmed before bending, or vice versa. For example, as previously described, a 3-D printed part may be printed on an assembly line, and the part may be printed on a COTS part.

[0121] Figure 3 An alternative exemplary configuration of a component production system 3000 is shown. Although various types of transport structure assembly are contemplated as described above, Figure 3 The examples in the description relate to a component production system 3000 for a vehicle in order to avoid unnecessarily obscuring the concepts of the present disclosure. Figure 3 , the component production system or facility 3000 may be comprised of vehicle subsystem areas (e.g., Figure 2 The facility 3000 may include one or more component production sections. For example, the facility may include a 3-D printed component production section 3100 and a COTS component production section 3200. Figure 3 Further shown are multiple subsystems 3600 in an assembly line where different tasks common to both 3-D printed parts and COTS parts may be performed.

[0122] In an exemplary embodiment designed to increase manufacturing flexibility and efficiency, Figure 3 The 3-D printed parts production section 3100 and the COTS parts production section 3200 can be operated in coordination with each other to facilitate the assembly of one or more types of automobiles. The coordination can be at least partially achieved by referring to Figure 1B The control system 1500 and database 1510 described above and the control system 1500 and database 1510 that can be connected to the network 1515 ( Figure 1B ) are implemented by automated builders 1520a-x and robotic devices that communicate with the control system 1500. These automated builders and robotic devices can autonomously move between one or more stations or assembly stations and / or perform different tasks (real time or otherwise) under the direction of the control system 1510 based on demand, availability, and other factors.

[0123] In the 3-D printed component production section 3100, old vehicles or old vehicle parts 3010 to be recycled can be disassembled to produce recyclable materials 3110 and unusable materials 3205. Unusable materials can be discarded from the system. Recyclable materials can be converted into ingots, such as by transferring the materials to a smelter. Ingots can be produced from metals of any source, including from sources other than disassembled old vehicles and old vehicle parts. Powder can be produced 3120 from ingots, such as via gas atomization in a powder production tower. Powder can be fed to one or more 3-D printers 3130. 3-D printed parts can undergo post-printing processing 3140, including processes such as surface treatment, cleaning and / or heat treatment. 3-D printed parts 3400 can be collected and stored 3150 in a first component hub location 3101. The first component hub location 3101 can further include one or more robots, such as an automated constructor, which is capable of transferring vehicle parts to a desired assembly line location. For example, 3-D printed parts can be dispatched from the first part hub location 3101 to various locations in the assembly line via one or more automated constructors. In some cases, the parts needed to build the suspension subsystem can be 3-D printed in the suspension part production area 3160. The 3-D printed suspension parts can be delivered directly to the suspension subsystem location 3070 in the assembly line. Alternatively, the 3-D printed suspension parts can be delivered to the first part hub location 3101 along with other 3-D printed parts, where they can then be dispatched to the suspension subsystem location 3070 in the assembly line. Alternatively, the suspension parts can be acquired as COTS products.

[0124] In the COTS component production section 3200, after receiving the COTS components 3210 from on-site production or from an off-site source, the COTS components can be CNC bent 3220 and / or cut 3230, such as via laser and water jet. Customized (e.g., via bending and cutting) COTS components 3500 can be collected and stored 3240 in the second component hub location 3300. The second component hub location 3300 can also include one or more robots, such as automated constructors, which can transfer the components to the desired assembly line location. The one or more robots at the first component hub location and the one or more robots at the second component hub location can be functionally equivalent. For example, customized COTS components can be dispatched from the second component hub location to various locations in the assembly line via one or more automated constructors.

[0125] In some cases, the components required to build the powertrain subsystem can be produced in the powertrain production area 3250. Alternatively, the components required to build the powertrain subsystem can be obtained as COTS parts. The powertrain components can be delivered directly to the powertrain subsystem position 3060 in the assembly line, or alternatively delivered through the first component hub or the second component hub. In some cases, the components of the interior subsystem can be produced in the interior production area 3260. Alternatively, the interior components can be obtained as COTS parts. The interior components can be delivered directly to the interior subsystem position 3080 in the assembly line, or alternatively delivered through the first component hub or the second component hub. In some cases, body wrap parts, such as body panels and glass, can be produced in the body wrap part production area 3270. Alternatively, the body wrap parts can be obtained as COTS parts. The body wrap parts can be delivered directly to the glass body subsystem position 3090 in the assembly line, or alternatively delivered through the first component hub position 3101 or the second component hub position 3300.

[0126] Some other assembly line locations to which parts may be transported include a dry mating location 3040 and a bonding and curing location 3050 .

[0127] Different robot assembly stations at different locations can be used for different stages of vehicle assembly and manufacturing. Different stations can be positioned in a manner that follows a logical progression. For example, a robot assembly station that performs a previous stage can be located adjacent to a robot assembly station that performs a subsequent stage. In some cases, a vehicle or vehicle component can follow a route or path, and each station can be positioned along the route or path or adjacent to the route or path. For example, a robot assembly station can be positioned so that these components travel along a substantially linear or circular path. In some cases, each assembly line position can include a robot assembly station. Throughout each position in the assembly line, there may be one or more robot arm exchange stations 3020 and one or more mobile robot arm pallets 3030 available. In some cases, the robot arm exchange station can be stationary, and the mobile robot arm pallet can be able to travel autonomously or with the aid of (e.g., pushing) another robot (such as an automated constructor) that can travel. The robot arm exchange station 3020 and the mobile robot arm pallet 3030 will be described in more detail below.

[0128] Figure 4Examples of additional assembly configurations are shown. Additional assembly configurations may optionally be used for low volume assembly. Low volume assembly configuration 4000 allows assembly of transport structure 4100, including assembly of vehicle structures, to be completed in as few as seven stations 4001-4007. Alternatively, assembly may be completed in less than or equal to seven stations for a particular vehicle, depending on the configuration. Assembly may be completed in a greater number of stations than previously listed. In some cases, each station may correspond to a robotic assembly station, each robotic assembly station including one or more automated constructors 4120 that perform a set of one or more vehicle manufacturing processes associated with each robotic assembly station. For example, the first station may include a set of vehicle manufacturing processes for node assembly 4001, the second station may include a set of vehicle manufacturing processes for panel assembly 4002, the third station may include a set of vehicle manufacturing processes for adhesive curing 4003, the fourth station may include a set of vehicle manufacturing processes for assembly 4004 of engine suspension components, the fifth station may include a set of vehicle manufacturing processes for interior assembly 4005, the sixth station may include a set of vehicle manufacturing processes for door and window trim 4006, and the seventh station may include a set of vehicle manufacturing processes for body panel installation and wrapping 4007. In other cases, each manufacturing stage may correspond to a robotic assembly station, each stage including one or more substations. For example, the first robotic assembly station may include substations in the first stage, including node assembly 4001, panel assembly 4002, and adhesive curing 4003. The second robotic assembly station may include substations in the second stage, such as assembly 4004 of engine suspension components. The third robotic assembly station may include substations in the third stage, including interior assembly 4005 and door and window trim 4006. The fourth and final assembly station may include sub-stations in the fourth stage, such as body panel installation and wrapping 4007.

[0129] Each station and / or robot assembly station can include three levels of action, including high-level action 4010, intermediate action 4020 and low-level action 4030. In some cases, the level of the action can be determined by the degree of participation of one or more automated constructors assigned to perform the task of the action. Alternatively or additionally, the level of the action may be determined by its difficulty. Alternatively or additionally, the level of the action can be determined by the degree of intervention (e.g., contact, manipulation, control, etc.) of the vehicle 4100 it is assembling. Alternatively or additionally, the level of the action can be determined by its proximity to the autonomous assembly platform 4105. For example, the transportation of parts and tools from the mobile supply vehicle 4130 to the autonomous assembly platform 4105 via the conveyor belt 4110 can be a low-level action, because the automated constructor only needs to perform simple tasks, such as transporting parts or tools between two locations, and the task is performed at a relatively long distance from the autonomous assembly platform (e.g., the end of the conveyor belt). For example, the action performed in the middle of the parts or tools on the conveyor belt can be a medium-level action. For example, an action performed at an autonomous assembly platform may be a high-level action.

[0130] Different vehicle parts or vehicle tools can be delivered as needed when needed. For example, different vehicle parts and / or tools can be transported between robot assembly stations or within a robot assembly station or transported from another location to a specific robot assembly station. Mobile supply vehicle 4130 and conveyor belt 4110 can conveniently and efficiently make the parts and / or tools required in the robot assembly station available to one or more automated constructors associated with the robot assembly station. For example, the mobile supply vehicle can approach the automated constructor to directly provide parts to the automated constructor. Alternatively, the automated constructor can approach the mobile supply vehicle to directly receive parts from the mobile supply vehicle. The mobile supply vehicle can also provide parts via an intermediate conveyor belt. Such a conveyor belt can transfer parts from one location to another without the help of any mobile supply vehicle. The conveyor belt can minimize or reduce the need for the automated constructor to travel to take out the parts. Autonomous assembly platform 4105 can be any platform capable of supporting one or more vehicle manufacturing processes. For example, platform 4105 can be configured to support the size and weight of the vehicle or other transport structure assembled on the platform. Platform 4105 can include any shape (e.g., substantially circular, angular, polygonal, free form, etc.) and any suitable area. In some cases, autonomous assembly platform 4105 can simply include an area of ​​the ground level ground (e.g., floor) of facility 4000. In other cases, autonomous assembly platform 4105 can be raised above ground level. Platform 4105 may be able to move up and down. Platform 4105 may or may not be able to move or rotate laterally. Autonomous assembly platform 4105 may be substantially parallel to the ground. Autonomous assembly platform 4105 can be configured to rotate clockwise or counterclockwise to allow one or more automated constructors to access different parts of the vehicle 4100 on the platform without one or more automated constructors themselves having to move through inconvenient paths (e.g., on, under, or through a conveyor belt) to access different parts of the vehicle. Automated constructors may be able to traverse the ground to move around platform 4105.

[0131] The assembly line may be monitored, such as via one or more quality control sensors 4140. The one or more quality control sensors 4140 may be fixed at a location with some freedom of movement (e.g., rotation, translation, tilt, etc.) or no freedom of movement throughout the facility 4000. Alternatively or additionally, the one or more quality control sensors 4140 may be included on one or more robots, such as automated constructors. The quality control sensors 4140 may provide quality control and feedback to one or more transport structure manufacturing processes in substantially real time, such as by comparing the assembled product to requirements in a desired design. The quality control sensors 4140 may be communicatively coupled to the control system 1500 ( Figure 1B) to send the sensed data to the control system, wherein the control system can provide instructions to one or more robots of the system, such as automated constructors, in response to the sensed data to continue, stop or change one or more actions they are performing. Sensors 4140 may include cameras, infrared sensors, other visual detectors (e.g., scanners, etc.), audio sensors (e.g., microphones), thermal sensors, thermosensitive sensors, motion detectors, and / or other sensors. The sensors can detect the visual and non-visual characteristics of any individual in a component, robot, tool, or assembly station. The sensors can capture one or more images, capture videos of components, track positions, states, and directions, and / or point errors with the aid of one or more processors. The data obtained from the sensors can be stored in a memory and / or analyzed with the aid of one or more processors. In addition, the data collected by the sensors and one or more processors can be transmitted to a remote user.

[0132] Figure 5 A schematic diagram of an additive manufacturing assembly system is shown. The additive manufacturing assembly system may include a node structure, including connectors (e.g., nodes) and interconnect materials that may be connected to each other via connectors. The interconnect materials may include various standardized structural materials, such as honeycomb panels, tubes, and extrusions. The connectors may be 3-D printed, such as in Figure 2 2130 in the component production area. Alternatively, the connector can be obtained as a COTS component and modified or used as is, depending on the implementation. The interconnect structure material can be 3-D printed, such as in Figure 2 2130 in the component production area. Alternatively, the interconnect structural material can be obtained as a COTS part. In some cases, such as when some parts of the connector and / or interconnect material are 3-D printed onto the COTS part, the connector and / or interconnect material can partially include the COTS part and partially 3-D printed material. Alternatively, unprinted structural materials can be manufactured within the facility.

[0133] Various connection techniques including the use of fasteners (e.g., screws) and adhesives (e.g., glue) can be used to assemble interconnected materials with another interconnected material via a connector. For example, a first tube and a second tube can each be fastened to a node via a fastener, thereby being joined by a node. In another example, a first tube and a second tube can each be fastened to a node via injecting an adhesive between a joint of a node and a first tube and between a joint of a node and a second tube, thereby being joined by a node. The connection method can temporarily or permanently connect the interconnected material to the node. The availability of 3-D printing can add great flexibility to the available connection methods. For example, fasteners, fixing features (e.g., holes with a specific diameter) for fixing fasteners, and / or channels for introducing adhesives can be custom designed and 3-D printed. In some cases, fasteners, features for fixing fasteners, and / or channels for introducing adhesives can be 3-D printed onto connectors or interconnected materials. Flexible fixing features can include screws, friction, and key-based interlocks, etc., which can enable a robotic assembly station to quickly and adaptively fix components.

[0134] In an exemplary embodiment, the additive manufacturing system 5100 can implement a robotic assembly system. The robotic assembly system can increase the production rate of complex transport structures. Figure 1A and Figure 1B ), a transport manufacturing facility may include a plurality of robotic assembly stations and a plurality of robots, such as an automated constructor and a mobile supply vehicle, associated with each assembly station. A plurality of robots may be configured within the robotic assembly station arrangement to collaboratively assemble and verify quality control of a transport structure passing through the assembly station. The robotic assembly station may include various specific features and / or sensors configured to enable rapid assembly of vehicle or other transport structure components, including 3-D printed components, COTS components, and / or non-printing facility manufactured components.

[0135] The robotic assembly system can be flexible in many ways. For example, the robotic assembly station can be configured to be able to adjust and assemble new and / or different structures without requiring significant adjustments to the robotic assembly system or its components (e.g., robots) such as fixation or reprogramming. For example, a designated location and / or designated area of ​​a robotic assembly station can be modified in real time. In some exemplary embodiments involving assembly of a vehicle such as an automobile, a plurality of robots can each be capable of performing a different vehicle manufacturing process, such that an existing robot can be instructed to perform a different vehicle manufacturing process without having to replace the robot with a different robot in order to perform the different vehicle manufacturing process.

[0136] The robot assembly station can be non-design specific. As described above, different vehicle models can share one or more robot assembly stations at the same time or at different times. For example, the robot assembly station can assemble structures to be used for various brands of vehicles, various models of vehicles, various categories of vehicles (such as trucks, trailers, buses, four-wheeled vehicles, etc.), and / or various categories of transportation structures (such as ships, airplanes, motorcycles, etc.). For example, various brands, models and / or categories of vehicles can be presented to the robot assembly station in any order, and the robot assembly station can continue to perform a collection of one or more vehicle manufacturing processes associated with the robot assembly station. Similarly, the robot may be non-specifically designed. The same robot can perform the same vehicle manufacturing process (e.g., welding) for various brands, models and / or categories of vehicles. In some cases, different robots may share the same tools for various brands, models and / or categories.

[0137] The robotic assembly system may include an additive manufacturing process. The additive manufacturing process may be vertically integrated, such as by combining a printing machine (e.g., a 3-D printing robot) and an assembly machine (e.g., various automated constructors) in a robotic assembly station. Non-printed structural materials may also be manufactured in a factory, for example, in small or large batches. For example, carbon fiber may be woven into a specific shape by one or more automated constructors (e.g., a carbon fiber robot). The carbon fiber material may be formed into a desired 3-D design, such as by changing the length of individual strands of carbon fiber. In some cases, non-printed structural materials may be produced on demand. This may be beneficial in reducing the inventory of discrete components. Inventory may include a large stock of raw materials for producing non-printed structural materials on demand.

[0138] In a robotic assembly station, multiple robots may be utilized to assemble components of a vehicle 5010. For example, some robots, such as mobile support vehicles, may be configured to collect 3-D printed components from a printer, collect standard and structural COTS materials, such as carbon fiber tubes, extrusions, and structural panels, and collect robotic arms from a robotic arm exchange center 5100 for transport. The mobile support vehicles may include a mobile support vehicle 5210 for carrying one or more vehicle components and a mobile support vehicle 5200 for carrying one or more robotic arms. For example, a mobile support vehicle 5210 may carry a fastener pallet 5140, a node pallet 5130, and / or a COTS extrusion pallet 5120. The same mobile support vehicle may carry more than one type of vehicle component. Alternatively, different mobile support vehicles may carry different types of vehicle components. In some cases, a mobile support vehicle may be specific to one or more types of vehicle components or tools.

[0139] Such as via pre-programmed instructions and / or from a control system such as Figure 1B The control system 1500 in the embodiment of the present invention may be discussed further below. Figure 6 The mobile support vehicle can move autonomously in whole or in part according to the instructions of the control system 6000 in the embodiment of the present invention. In some cases, the mobile support vehicle may include one or more sensors (e.g., cameras, geolocation devices such as GPS, etc.) that communicate with the control system so that the control system can track the location of the mobile supply vehicle. In an exemplary embodiment, the control system can use the tracked location to form and send instructions. The mobile supply vehicle can roll, rotate, walk, slide, float, fly and / or perform a combination of the above to travel from one position to another. The mobile support vehicle can move freely within a parameter or a set of parameters, along a surface, and / or along a track (laterally, longitudinally, etc.). In some cases, the mobile support vehicle can be configured to travel so that the base moves relative to the surface below (e.g., the ground, a rope, the side of a wall, the side of a column, etc.). For example, the mobile support vehicle may include a mobile component and a non-mobile component. A mobile component such as a wheel, a belt, a limb, a wing or other component (e.g., a gear, etc.) can move relative to the non-mobile component so that the non-mobile component moves relative to the surface below.

[0140] In an exemplary embodiment, some robots, such as automated constructors, may be configured to assemble components, secure components, and apply fasteners and adhesives to vehicle components. The automated constructor may be secured in a position with limited freedom of movement (e.g., rotation, rotation of limbs (if present), etc.). Alternatively or additionally, the automated constructor may move autonomously or semi-autonomously, such as via pre-programmed instructions and / or from a control system (e.g., Figure 1B Control system 1500 or Figure 6 The automated builder may be free to traverse the underlying surface. The automated builder may be free to move in any lateral direction without obstacles or obstructions. The automated builder may include one or more processors onboard the automated builder that may generate commands to control the movement of the builder. The commands may be generated in response to and / or based on data collected by one or more sensors onboard the automated builder.

[0141] In an exemplary embodiment, the automated constructor may include one or more sensors (e.g., cameras, geolocation devices such as GPS) that communicate with the control system so that the control system can track the location of the automated constructor. In some cases, the control system can use the tracked location to form and send instructions. The automated constructor can roll, rotate, walk, slide, float, fly and / or a combination of the above to travel from one position to another. For example, the automated constructor may include one or more wheels that can roll to propel the automated constructor. The automated constructor can move freely within parameters, along a surface and / or along a track (laterally, longitudinally, etc.). In some cases, the automated constructor may be configured to travel so that the base moves relative to the surface below (e.g., the ground). For example, the automated constructor may include at least one mobile component and a non-mobile component. Mobile components such as wheels, belts, limbs, wings or other components (e.g., gears, etc.) can move relative to the non-mobile component so that the non-mobile component moves relative to the surface below.

[0142] The automated constructor may include robots such as a bonding robot 5330 for bonding, a fixture robot 5320 for handling fixtures, a 3-D printing robot 5310 for printing 3-D parts or for supporting a separate 3-D printer, a bolting robot 5340 for bolting, an arm replacement robot 5220 for replacing the arms of other robots, an extrusion robot 5300 for handling extrusions such as for producing extrusions and / or installing extrusions, a press robot ( Figure 5 ) and a welding robot ( Figure 5 3-D printing robots may include robots equipped with 3-D printers. The 3-D printing robots may travel autonomously or semi-autonomously like other automated constructors. The mobile 3-D printing robots may travel to assembly lines or other work areas (e.g., platforms) as needed and print directly on vehicles, vehicle parts, and / or vehicle accessories.

[0143] Various other robots can perform mechanical processes such as cutting (e.g., via water jets, laser cutters), bending (e.g., CNC machine bending), and milling (e.g., to accept inserts and allow panels to conform to specific shapes). Alternatively, mobile support vehicle robots can transport parts that require mechanical processing to other machines.

[0144] The automated constructor may be configured to perform a vehicle manufacturing process with or without the assistance of one or more tools. For example, a 3-D printing robot may be configured to perform a 3-D printing process with the aid of a 3-D printer. One or more tools (e.g., a 3-D printer) may be a permanent or removable part of the automated constructor. In some cases, the automated constructor may include one or more robot arms 5110. One or more robot arms may be permanently attached to the automated constructor or may be detachable from the automated constructor. In one example, the arm may have a tool that may be attached to the arm, and the arm may be swapped out as needed to exchange the tool. In another example, the arm may remain attached to the automated constructor, but a tool such as an end effector may be swapped out from the arm. The robot arm may include an interchangeable end effector that is capable of performing a variety of tasks (e.g., chassis assembly, battery assembly, body panel assembly, painting, human weightlifting assistance, application of fasteners, application of adhesives, application of paint, fixation of components for curing, etc.). In some cases, the end effector may be interchangeable. Alternatively or additionally, a robot arm including an end effector may be interchangeable. In some cases, one or more tools may become available at various stationary positions. For example, one or more arms including interchangeable end effectors may become available at various fixed arm exchange areas 5100 where the robot can access the exchange arm. Alternatively, tools such as one or more arms including interchangeable end effectors may become available on a mobile support vehicle 5200, which is configured to transport one or more arms to various locations accessible by other robots. In some cases, a mobile support vehicle carrying one or more arms may deliver the arm to a specific robot. The available robot arms may be non-design specific. For example, different robots may use the same arm at different points in time to perform vehicle manufacturing processes on different models and / or categories of vehicles. In some cases, the robot arm may be compatible with any automated constructor, so that any automated constructor can use the robot arm. In other cases, the robot arm may be compatible only with a certain type of automated constructor, so that only a specific type of automated constructor can use the robot arm.

[0145] In one example, a robotic assembly station can simultaneously coordinate the insertion of multiple tubes into a node from various angles using one or more automated constructors including one or more robotic arms, introduce bolted secondary features, and then inject adhesive via 3-D printed channels. A fixture robot can then apply external fixtures to provide proper position during curing.

[0146] Figure 6A schematic diagram of an assembly system control system 6000 is shown. In some cases, the assembly system control system 6000 and the operation of the assembly system control system may correspond to Figure 1B The control system 1500 and Figure 1B The control system 1500 in the embodiment of the present invention is described in detail. The control system 6000 may include known computing components, such as one or more processors, one or more storage devices storing software instructions executed by one or more processors and data. The one or more processors may be a single microprocessor or multiple microprocessors capable of executing a specific instruction set, a field programmable gate array (FPGA) or a digital signal processor (DSP), or some combination of these components. Computer-readable instructions may be stored on a tangible, non-temporary computer-readable medium, such as a floppy disk, a hard disk, a CD-ROM (Compact Disc Read Only Memory), an MO (Magneto-Optical), a DVD-ROM (Digital Versatile Disk Read Only Memory), a DVD RAM (Digital Versatile Disk-Random Access Memory) or a semiconductor memory. In some exemplary embodiments, the control system may use cloud storage, such as any future storage technology that may be key to the Internet of Things (IoT). Alternatively, the methods disclosed herein may be implemented in hardware components or a combination of hardware and software, such as, for example, an ASIC (Application Specific Integrated Circuit), a special-purpose computer or a general-purpose computer.

[0147] The network 6010 may be configured to connect and / or provide communication between various components (e.g., one or more automated constructors 6200, one or more mobile supply vehicles 6300, etc.) and the control system 6000. For example, the network may be implemented as the Internet, an intranet, an extranet, a wireless network, a wired network, a local area network (LAN), a wide area network (WAN), Bluetooth, near field communication (NFC), a wireless network, ... Figure 6 Any other type of network or any combination of the networks listed above that enables communication between one or more components of the network layout in the embodiment of the present invention. In some embodiments, the network can be implemented using a cell and / or paging network, satellite, licensed radio, or a combination of licensed radio and unlicensed radio. The network can be wireless, wired (e.g., Ethernet), or a combination thereof.

[0148] The control system 6000 may be implemented as one or more computers storing instructions that, when executed by one or more processors, may generate instructions and send the instructions to one or more automated builders 6200, one or more mobile supply vehicles 6300, other robots, and / or machines in an assembly system. The control system may further receive data and / or instruction requests from one or more automated builders, mobile supply vehicles, other robots, and / or machines in an assembly system. Although Figure 6A single control system 6000 is shown, but in some embodiments, a vehicle manufacturing facility may include one or more control systems, each of which operates substantially in parallel with the control system 6000 and / or in conjunction with the control system 6000, such as via a network 6010. Alternatively or additionally, the control system 6000 may be distributed throughout different locations within the facility. For example, a vehicle manufacturing facility may include a main control system and an ERP system, wherein the ERP system is embedded as part of the main control system. In some cases, a single computer may implement one or more control systems. Alternatively, one or more control systems may be implemented on separate computers. In some configurations, one or more control systems may be software stored in a memory accessible by other control systems (e.g., in a memory local to the other control systems or in a remote memory accessible via a communication link such as a network). In some configurations, for example, one control system may be computer hardware, and another control system (e.g., an ERP system that directs a 3-D printer) may be software that may be executed by another control system.

[0149] One or more control systems 6000 may be used to control various components of a vehicle manufacturing facility in a variety of different ways, such as by storing and / or implementing software that executes one or more algorithms to implement control. Although multiple control systems for executing one or more algorithms have been described, it should be noted that a single control system consistent with the disclosed embodiments may be used to execute some or all of the algorithms.

[0150] In some cases, one or more control systems may be connected or interconnected to one or more databases, such as Figure 1B 1510 in. One or more databases may be one or more memory devices configured to store data (e.g., sensor data, component manufacturing data, inventory data, etc.). In some exemplary embodiments, one or more databases may also be implemented as a computer system with a storage device. In one aspect, the control system 6000 may use one or more databases to perform one or more operations consistent with the disclosed embodiments. In certain exemplary embodiments, one or more databases may be co-located with the control system and / or co-located with other components (e.g., automation constructor 6200) on a network that may or may not be network 6010. For example, the automation constructor 6200 may send sensor data to one or more databases without passing through the control system. It will be appreciated that one or more other configurations and / or arrangements of one or more databases are also possible.

[0151] The control system 6000 can communicate with multiple users, such as through a network 6010. For example, one or more users, such as a first user 6020a and a second user 6020b, can communicate with the control system. Users (e.g., administrators of vehicle manufacturing facilities, plant managers, etc.) can participate in the system to monitor the vehicle manufacturing process (e.g., robot activities, production efficiency, quality control, etc.) and / or give instructions to various components of the vehicle manufacturing facility (e.g., robots, machines, etc.). Communication can be unidirectional, such as from a user to a control system (e.g., commands, instructions, etc.) or from a control system to a user (e.g., alarms, notifications, commands, instructions, etc.). Alternatively, communication can be a two-way communication between a user and a control system. In some cases, a user can communicate with other users of the system. Users can be associated with a facility and can include individuals or entities, such as administrators of the facility, employees of the facility, designers of vehicle models or other transportation structures manufactured by the facility, and customers or potential customers of the facility. Instructions provided to the command system by users can be real-time instructions (e.g., after manufacturing a vehicle) or regular instructions at regular or irregular intervals (e.g., initiation of assembly or design, regular inspections at key stages, etc.). In some cases, the instructions may be at a high level, such as commanding the start or stop of an accessory or otherwise initiating a pre-existing protocol, where the control system may then autonomously or semi-autonomously execute the user command. In some cases, the instructions may be more detailed, such as controlling individual paths of a robot, controlling the travel path of a vehicle component, and controlling a schedule.

[0152] The user may communicate with the system by means of the user device 6030a, 6030b that may include an interface. For example, the first user may communicate with the system by means of the first user device that includes an interface, the second user may communicate with the system by means of the second user device that includes an interface, the nth user may communicate with the system by means of the nth user device that includes an interface, and so on.

[0153] The user devices 6030a, 6030b may be mobile devices (e.g., smart phones, tablet computers, pagers, personal digital assistants (PDAs)), computers (e.g., laptops, desktop computers, servers), or wearable devices (e.g., smart watches). The user devices may also include any other media content players, such as set-top boxes, televisions, video game systems, or any electronic devices capable of providing or presenting data. The user devices may optionally be portable. The user devices may be handheld. The user devices may be network devices capable of connecting to a network, such as a local area network (LAN), a wide area network (WAN) such as the Internet, a telecommunications network, a data network, or any other type of network.

[0154] The user device may include a memory storage unit, which may include a non-transitory computer-readable medium containing code, logic or instructions for performing one or more steps. The user device may include one or more processors capable of performing one or more steps, for example according to a non-transitory computer-readable medium. The user device may be, for example, one or more computing devices configured to perform one or more operations consistent with the disclosed embodiments. The user device may include a display showing a graphical user interface. The user device may be capable of accepting input via a user interaction device. Examples of such user interaction devices may include a keyboard, button, mouse, touch screen, touch pad, joystick, trackball, camera, microphone, motion sensor, thermal sensor, inertial sensor, or any other type of user interaction device. The user device may be capable of executing software or applications provided by one or more authentication systems. For example, a user (e.g., a facility manager, a plant manager, etc.) may input instructions to the control system through a user device to be forwarded to one or more robots or machines. In another example, the user may reprogram the control system, such as for re-optimization of the vehicle manufacturing process or for software updates. In another example, such as for safety considerations, the user may have the option of sending an emergency stop command, which may stop the operation of all robots and / or machines operating in the vehicle manufacturing facility.

[0155] The control system 6000 can be configured to generate instructions for one or more automated constructors 6200 and / or one or more mobile supply vehicles 6300 to and from each assembly station. For example, the control system can instruct one or more automated constructors to autonomously travel to and from each assembly station. Alternatively or additionally, the control system can provide more detailed (e.g., step-by-step) instructions to one or more automated constructors to travel to and from each assembly station. In some cases, the control system can change the designated position and / or designated area of ​​the robot assembly station 6100, 6120 such as by indicating the travel of one or more automated constructors associated with the robot assembly station. Alternatively or additionally, the robot can have pre-programmed instructions that the control system may or may not cover. In this regard, the robot assembly station can be flexible and modular, and the manufacturing facility can be easily reconfigured by changing the corresponding position and / or area of ​​each robot assembly station within the limits of the facility location and / or facility area. In some cases, the control system can provide instructions to the component (e.g., mobile supply vehicle 6300) in coordination with other components in the same robot assembly station. For example, the control system 6000 may issue instructions to all robots associated with the first robotic assembly station 6100 to cease any and all operations and proceed to the second robotic assembly station 6120 .

[0156] In an exemplary embodiment, the control system 6000 can generate instructions in real time. Real time can include a response time of less than 1 second, one tenth of a second, one hundredth of a second, or one millisecond. Depending on the implementation, each of the one or more robots 6200, 6300 (such as those described above or further described below) may be able to respond to instructions from the control system in real time. For example, through the movement of one or more automated constructors, a robotic assembly station can be reconfigured and scaled in real time in position and / or area.

[0157] The control system 6000 can be further configured to generate instructions for one or more automated constructors 6200 to perform one or more manufacturing processes, or one or more sets of one or more manufacturing processes, for a vehicle or other transport structure. The control system can give detailed instructions to one or more automated constructors regarding the execution of a manufacturing process. For example, the control system (such as through an ERP system) can give specific dimensions of a vehicle part to a 3-D printing automated constructor for printing.

[0158] In another example, instructions pre-programmed in the robot and / or from a control system such as Figure 1B The control system 1500 and / or Figure 6 The robot may freely move to and from and within a robotic assembly station within the constraints of instructions received by the control system 6000 of the robot and / or instructions learned by the robot via machine learning. The robot may be able to receive and post-process 3-D printed parts, and deliver 3-D printed parts to a robotic assembly station for incorporation into a complex structure (e.g., a chassis). Different robotic assembly stations may be placed next to or around one or more assembly lines, such as for efficiency, which may enable materials to pass through different robotic assembly stations as the process proceeds.

[0159] Figure 7 An example of a robotic automation system is shown. The robotic automation system 7000 may include one or more automated constructors 7200, a conveyor belt 7500 for transporting one or more transport structure components 7300, 7400, a sensor 7600, and one or more processing tools 7100. Alternatively, the system may include a transportation system that can replace the conveyor belt, such as other mobile platforms, mobile robots, and / or manual labor. The robotic automation system can support various processes performed in a manufacturing facility, such as manufacturing, testing, inventory, pre-use, recycling, or disposal processing. The processes performed by the robotic automation system may be constructive, protective, or deconstructive, as appropriate to the stage of the life cycle of the component of the transport structure being processed.

[0160] One or more automated constructors 7200 and / or one or more processing tools 7100 can be mobile so that they can travel to very large, permanently installed or stored components. Alternatively or additionally, a conveyor belt 7500 can convey one or more automated constructors and / or one or more processing tools toward one or more components 7300, 7400. Alternatively or additionally, one or more components can be conveyed toward one or more automated constructors and / or one or more processing tools. Whether the automated constructor and process tool are moved and / or whether the vehicle component is moved may be a consideration of economic and mechanical efficiency. For example, it may be more economical and mechanically efficient to move the smaller and / or lighter of the two toward the larger and / or heavier of the two. In some cases, if the one or more vehicle components to be processed are part of a larger component that is not convenient to move (e.g., via assembly, installation), the one or more vehicle components can first be separated and disassembled from its installation by one or more disassembly automated constructors. Once one or more automated constructors and one or more vehicle components are brought within the range of another, the one or more automated constructors can perform the indication process. In one example, the automated constructor optionally includes additive manufacturing or 3-D printing machinery to construct replacements for worn or damaged vehicle parts. One or more automated constructors can exchange robotic actuators through available processing tools. Alternatively, one or more automated constructors can exchange robotic arms with different actuators.

[0161] Sensor 7600 can be communicatively coupled to a control system, which in turn is communicatively coupled to one or more automated constructors. Alternatively, the sensor can communicate directly with one or more automated constructors and / or one or more processing tools. In some cases, the sensor can be an imaging device, such as a camera. In some cases, the sensor can be a thermal sensor, a motion sensor, an audio sensor (e.g., a microphone), etc. The sensor can monitor (e.g., quality control checks, etc.) the transport structure manufacturing process. For example, sensor 7600 can determine the stage of the life cycle in which one or more vehicle components are located, and send these data to the control system, which can then instruct one or more automated constructors to perform processes suitable for a specific life cycle. Sensor 7600 can also detect wear and tear or damage to one or more components, such as by instructing one or more automated constructors through a control system to participate in additive manufacturing or 3-D printing to build a replacement for the worn or damaged component. In one example, a sensor can be used to inspect a fixture or seal along a pipeline to remove the worn component and manufacture and install a new component, where the worn component is removed.

[0162] Figure 8An example of a structured subassembly is shown. In an exemplary embodiment, a robotic assembly station can be used to assemble a structure composed of prefabricated components, such as nodes 8100a, 8100b, arcs, and tubes 8200. In some cases, such assemblies may require that multiple components be inserted into other components (e.g., nodes, arcs, tubes, etc.) in a coordinated manner (e.g., simultaneously, specifically timed, etc.). Such coordinated insertion can prevent geometric binding of the structure. In some cases, the subassembly structure 8300 can be incorporated into a larger assembly 8200.

[0163] In an exemplary embodiment, each component, accessory and / or sub-assembly structure may include one or more tags. The tag may include an identification matrix, such as matrices 8110a, 8110b, and 8310b. The tag may be used to detect and identify the component, determine the position, location and / or orientation of the component, detect errors, and / or track and monitor the component throughout the manufacturing process and / or throughout the life cycle of the component. For example, the tag may be used to verify the correct orientation and position of the component, accessory and / or sub-assembly structure relative to another. The tag may be detected by one or more sensors (e.g., cameras) located on the assembly line and / or on the automated constructor. After verification via the tag, the component, accessory and / or sub-assembly structure may be assembled, such as via a single-motion press-into-place action, in which coordinated forces are applied from several directions. The coordinated forces may be programmed or indicated (e.g., in real time) to be simultaneous or specifically timed. The single-motion press-into-place action or other insertion actions may be performed by one or more robots in a robotic assembly station, such as one or more automated constructors.

[0164] Fig. 9 An example of a disassembly area is shown. The disassembly area can reverse the assembly line process for large parts to achieve flexible disassembly. Old transport structures or transport structure components can be disassembled, such as via one or more automated constructors configured for disassembly. Disassembled components may be recycled, refurbished, or discarded based on their respective conditions. This can be done, for example, by Figure 7 The sensor 7600 in the embodiment of the present invention can be used to check the condition of the disassembled components. Alternatively, one or more sensors can be located on a robot such as a disassembly automated constructor to check the disassembled components. In some embodiments, such as via an identification matrix (such as Figure 8The matrices 8110a, 8110b, 8310b in the figure identify the stages of the life cycle of the disassembled parts, and the condition of the disassembled parts can be embedded in the disassembled parts. The control system can give instructions, or one or more robots can be pre-programmed to determine whether the parts are recycled, refurbished or discarded. For example, glass from the glass body 9100, selected suspension components from the suspension subsystem 9200, selected internal components from the internal subsystem 9300, and carbon materials from other subsystems 9400 can be determined to be recyclable and sent to the smelter to be turned into ingots. Other components, such as selected body parts, wheels, tires, and engines can be determined to be able to be refurbished and transported to a storage area. In some cases, nodes disassembled from one or more subsystems can be determined to be recyclable and transported to a smelter. In some cases, the nodes may be hooked to the suspension components before being transported to the smelter.

[0165] In some cases, Figure 5 The additive manufacturing system may further include a plurality of sensors. The plurality of sensors may ensure the correct assembly and quality control of a complex structural system assembled in a robotic assembly station. One or more sensors may be installed in the robotic assembly station. Alternatively or additionally, one or more sensors may be positioned on one or more robots associated with the robotic assembly station, such as an automated constructor. Alternatively or additionally, one or more sensors may be integrated into the structural product produced by the system. One or more integrated sensors may provide critical feedback during the assembly process and may provide continuous information about the product throughout its life cycle. One or more sensors may be positioned to support proper positioning and tolerance stack-up. One or more sensors may further detect appropriate or inappropriate performance of product specifications.

[0166] In some cases, 3-D printed parts and / or structures can be configured to accept and / or combine one or more sensors. One or more sensors combined can travel with 3-D printed parts and structures, and / or final products. By tracking printed parts and structures, and / or final products through one or more sensors combined, the control system can monitor product quality. In an example, a stress sensor can track and monitor the torsional performance of a vehicle that has integrated a stress sensor under specific driving conditions. For example, the expected stress can be measured at the time of production, and then can be related to the empirical stress value measured at a later time when the vehicle performs similar operations. Such monitoring may provide early warning of potential failures and product liability injuries, and then provide feedback to the manufacturing facility to improve the strength of components in potential risk areas. In other examples, the system can obtain frequency response measurements and / or acoustic measurements from integrated sensors to perform similar analysis.

[0167] Fig.10 An example of a robot automation system with integrated sensors is shown. The system 10000 may include a first conveyor belt 10100 for transporting a first component 10300, a first component monitored by a first sensor 10800 and a second conveyor belt 10200 for transporting a second component 10400, a second component monitored by a second sensor 10900, a subassembly structure 10600, a third component 10500, and one or more automated constructors 10700. For example, the first sensor and the second sensor may include an overhead 3-D sensor (e.g., Kinect or LIDAR) capable of tracking the position of two arms of one or more automated constructors and one or more individuals (e.g., human operators) present in an assembly station. The sensor may be configured to project potential movement paths and preemptively prevent collisions between humans and robots. Alternatively or additionally, when one or more individuals are determined to be in the vicinity of one or more automated constructors, such as by giving instructions through a control system, the operator of the assembly station may manually limit the range of motion and / or speed range of the robot. Beneficially, this system may protect the safety of personnel and maximize production throughput when personnel safely leave the station. In some cases, sensors may track an individual wearing a headset with an augmented or virtual reality overlay. In some cases, a virtual or augmented reality overlay of the assembly sequence and component placement may be provided to the individual through the headset, where the overlay is aligned with the current configuration of the assembly sequence and component placement in the assembly station to assist the individual in participating in the assembly and / or train the individual.

[0168] In some cases, the first sensor and the second sensor may include a camera and a data recorder that can capture, record, store, transmit and / or share an image or image sequence of the assembly sequence using a control system, such as to a Figure 1B One or more databases 1510 in the system. Alternatively, the images or image sequences may be captured, recorded, stored, transmitted and / or shared directly with other control systems, such as control systems with other manufacturing facilities. In some cases, a database may be created to record the complete manufacturing process. A database of the entire manufacturing process may enable the performance of a complete financial, efficiency and / or environmental analysis of the end-to-end manufacturing process.

[0169] In some cases, a robotic automation system can support motorized interaction between an individual (e.g., a factory worker, etc.) and a vehicle, product, and / or structure being assembled. For example, the system can include automated and / or semi-automated mechanisms and equipment, such as robots and exoskeleton-like lifting and gripping devices for material handling.

[0170] In other exemplary embodiments, one or more robots (such as an automated constructor) may include a machine-based learning algorithm (or algorithm suite) for dynamically learning tasks on the fly. In these embodiments, such a robot can learn tasks or details about tasks, such as spot welding based on observations and / or direct experience via the robot's sensors. For example, if an error occurs during a particular task process that the automated constructor is performing, the automated constructor's machine-based learning capabilities can enable it to identify the cause of the error and possible or approximate solutions. In another exemplary embodiment, a machine-based learning algorithm is embedded within the robot itself and coordinated periodically or in real time (or near real time) by instructions from a control system, which can govern machine learning algorithms, such as settings, activations, and the like.

[0171] In an exemplary embodiment, the automated constructor uses machine-based learning to avoid collisions. In a manufacturing plant where many robots may be moving back and forth between various destinations and humans may be interspersed among the robots, it may be important to take additional safety measures as appropriate to prevent or at least minimize accidental damage to equipment or avoid injury. One such safety measure may include using machine-based learning to enable a robot, such as an automated constructor, to monitor the movement of other machines, understand the type and pattern of such movement, and monitor other parameters related to the movement, such as the speed, acceleration, rotational capacity, etc. of the other machines. Monitoring movement patterns through self-learning algorithms can enable the machine to continuously improve its ability to safely navigate facilities by recognizing the patterns of other machines and recording data related to speed and movement and other parameters.

[0172] Therefore, in some cases, one or more robots may be able to perform machine-based learning. Machine-based learning can enable partial or full autonomous behavior of the robot. For example, the robot may be able to determine and perform future actions based on past actions. Machine-based learning can enable the robot to automatically (e.g., independently and without pre-programmed instructions) or semi-automatically (e.g., with minimal instructions such as assigning the robot to an assembly station) use the correct support materials (e.g., structural panels, adhesives, other nodes, other components or structures, etc.) to assemble certain components (e.g., pipes, nodes, etc.) to their desired positions to deliver finished products. In another example, machine-based learning can enable the robot to autonomously travel to a target destination or even determine a target destination. Machine-based learning can be independent of the robot, such as an automated constructor or a mobile supply device. Alternatively or additionally, machine-based learning can occur at the assembly station level so that learning is assigned to all robots associated with the assembly station. Alternatively or additionally, machine-based learning can be at the control system level so that learning is assigned to all components connected to the control system. For example, machine-based learning at the control system level may improve the ability of the control system to coordinate different components of a vehicle manufacturing facility with no or minimal user instructions.

[0173] Figure 19A-19B A flow chart of a method for automated assembly of a transport structure according to an exemplary embodiment is shown. Fig.19A , at step 1910, a first portion of a transport structure is assembled by a first automated builder at a first robotic assembly station. Although a "first" portion of a transport structure, a "first" automated builder, and a "first" station are described for purposes of this description, it will be understood that more than one portion of a transport structure, more than one automated builder, and / or more than one station may alternatively or additionally be used. At step 1920, a second portion of the transport structure is assembled by a second automated builder at a second robotic assembly station.

[0174] Concurrently with or subsequent to the above steps, a number of flexible and configurable operations may occur, such as to maximize build time, efficiency, to reconfigure the assembly system, or for other reasons discussed in this disclosure. For example, at step 1930, the first automated builder or the second automated builder may be moved between the first station and the second station in an automated manner during assembly. As another example, at step 1940, the transport structure itself or its components may be moved between robotic assembly stations in an automated manner, such as via a conveyor belt, as it is assembled.

[0175] Reference Fig.19B, in step 1950, the first automated constructor or the second automated constructor may be reprogrammed to perform a different function. Like the above steps, this process may occur before, during, or after assembly, and may also occur between complete assembly of different models of transport structures or different types of transport structures. In step 1960, one or more of the robotic assembly stations may be moved to another location, either in real time or as an artifact of a preprogrammed set of instructions. For example, in step 1970, components or parts used in connection with or as part of the assembly of a transport structure may be transported in an automated manner between robotic assembly stations for assembly of the transport structure at those stations.

[0176] In step 1980, as discussed further above, the automated transport structures may learn new tasks and modify their actions due to machine-based learning techniques. As disclosed herein and in step 1990, any of these steps may involve the control system providing instructions to one or more automated constructors directly or indirectly (where the instructions may be sent in real time), as part of a pre-programmed instruction set, or as an update provided on a periodic basis.

[0177] In another exemplary embodiment, the system can be open to customer participation in the construction process. Customers such as companies, small teams and / or individuals can use the web-based design and optimization solution to design the desired structure of the desired transport structure with a high degree of flexibility, and produce and assemble the design using the limits of tool and facility availability via variable robotic assembly stations, variable automated constructors and 3-D printing technology.

[0178] For example, the assembly stations may be programmed and configured using abstract and / or high-level languages ​​accessible to non-programmers and non-technical individuals. This accessibility may allow end customers (including companies, small teams, and individuals) to instruct one or more robotic assembly stations to assemble their own customized transport structures in any capacity without the assistance of technicians or other experts. For example, end customers may be allowed and able to instruct and direct robotic motions and sequences to produce and assemble their own customized vehicles. For example, end customers may communicate with control system 6000 as users 6020a, 6020b over network 6010. Alternatively or additionally, end customers may communicate with control system 6000 via a cloud or server (such as Figure 1B The control server 1505 of the robot communicates with the control system. The end customer can, for example, use a user device including a user interface (e.g., such as user devices 6030a, 6030b) to provide user input (e.g., instructions) to guide the robot movements and sequences to produce and / or assemble a vehicle or other structure.

[0179] In some cases, the end customer may provide user input via a web interface or virtual reality interface provided by the control server. In an example, a sensor-integrated robotic automation system may track and record the direction of an individual's movement, motion, and / or gaze (such as via the individual's virtual reality headset), and provide such data to the end customer through the end customer's virtual reality headset, which the end customer may use as a selection of user devices. The end customer may experience virtual or augmented reality during the end customer's purchase and / or assembly experience. In the case where the end customer participates in their own build, they may meet some homologation requirements associated with participating in the build event.

[0180] In some cases, the manufacturing facility may be configured to enable smart video conferencing or other messaging. For example, the facility may be equipped with an integrated smart video conferencing and / or messaging system to enable rapid electronic communication across the facility or outside the facility via voice or other commands. The smart video conferencing and / or other messaging system may enable the end customer to communicate with employees (e.g., operators, workers, etc.) of the facility in real time during the build of the customer's vehicle and allow for the removal of oversight and in-process intervention during the build process if desired by the end customer.

[0181] In some cases, a sensor-integrated robotic automation system can capture photos and / or videos of a particular customer's vehicle through its manufacturing and assembly process. The system can further collect test results and inspection measurements at each key step of the manufacturing and assembly process. A historical and complete database of the manufacturing and assembly process for a particular vehicle can be generated for all vehicles manufactured at the facility. The database can be provided to the customer. Alternatively or additionally, the information in the database can be analyzed, such as for research and development.

[0182] In lower volume production facilities, or in operations where an artistic touch or some level of improvisation is desired (e.g., painting, designing), a remote customer or operator can access the manufacturing and assembly process via the Internet through a web interface or virtual reality interface, such as through the methods previously described, to provide instructions (e.g., directing robotic movements, etc.) to aid in the assembly process of the structure.

[0183] In some cases, the manufacturing facility may further include an additive manufacturing part identification system. The identification system may accurately enable the repeated assembly of complex structures. Accurate identification of parts and information associated with the parts may have beneficial applications in various operations such as security, manufacturing, assembly, distribution, logistics, fraud verification, sales, maintenance repair, storage, processing, recycling and disposal.

[0184] As briefly described above, the identification system may include a label, such as an identification matrix. The label may be adhered as a label or sticker etched, printed or attached to a vehicle component or structure. Fig.11 An example 11000 of a component 11100 with an integrated tag 11200 is shown. For example, the tag 11200 can be integrated in any location on the surface of the component 11100.

[0185] Fig.12 An example of a label is shown. Label 12000 may be any type of graphical mark that is machine readable, such as an identification matrix. The label may include descriptive data that may or may not be encoded. The descriptive data may include data such as symbol format, data character encoding method, capacity, size characteristics, error correction rules, encoding and decoding algorithms, user selectable application parameters, and unique units of information.

[0186] Tag 12000 may be associated with a database that may be stored in a separate database such as Figure 1B The unique information in one or more databases 1505) of the control system (such as Figure 1B For example, when reading a tag, the robot and / or control system may communicate with and search one or more databases for the tag to find unique information associated with the tag.

[0187] In an example, tags such as identification matrices may simply identify the components and subsystems they are to become a part of. A catalog of required assembly information, which may include information such as which subsystems require which components, may be stored in one or more databases. In another example, a tag may simply identify final product requirement information. Based on the final product requirement information, a robot (e.g., an automated builder) may perform one or more vehicle manufacturing processes that conform to the final product requirement information via machine learning. In another example, a tag on a component may provide detailed information about a component or component assembly, such as relationship information (e.g., the location and position of one component relative to another component or another accessory). Relationship information may disclose a specific accessory to which a component or another accessory (e.g., a sub-accessory) is to be combined. Detailed information (including relationship information) may be stored in one or more databases accessible to one or more robots and / or a control system that read the tag, so that the control system and / or one or more robots may find detailed information associated with the tag.

[0188] In some cases, a label on a part can provide grip point information. For example, for a part, a label on the part may disclose the presence of a handle or threaded hole specifically designed for gripping, or a flat, smooth surface that may be compatible with a suction cup. The corresponding location of one or more grip points can be described by coordinates relative to the label location. Such information can help a robot (e.g., an automated constructor) determine the appropriate gripper approach path and grip angle when grasping the part.

[0189] Fig.13 A flow chart 13000 of a life cycle of a 3-D printed component with an integrated tag is shown. For example, a 3-D printed component 13400 may be a component of an automotive subsystem, an aircraft or air conditioning component, or some other useful object for industrial, military, commercial, or consumer use. In a first step 13100, a component may be specified. In the component specification, the component requirements (such as size and function) may be identified as well as its unique identifying part number or name. The component specification may be compiled for use in subsequent steps. In a second step 13200, a tag may be created, wherein the tag is associated with descriptive data about the component. The descriptive data may be stored in one or more databases accessible by a control system. The descriptive data may or may not be encoded in the tag. If encoded, the tag may be encoded using a standard (e.g., ISO / IEC 18004 standard) or a non-standard algorithm. The tag may be machine readable.

[0190] In the next step 13300, the component can be designed, such as on a computer (e.g., via computer-aided design (CAD) software and / or selected from a library of pre-designed or standard components). A three-dimensional model or design form of the component can be defined. The label of the component created earlier can be integrated into the three-dimensional model or design of the component. The component can have multiple labels. A descriptive computer 3-D data model 13400 of the component with integrated labels can be generated. The 3-D data model can be stored as a computerized descriptor file in a transmittable digital format (e.g., STEP, STP, SLDPRT, EPRT, etc.). The descriptor file can include various entries of data and metadata, including part numbers, physical dimensions, shapes, colors, material specifications, weights, geometric tolerances, and / or other text and symbolic descriptions. In the process of saving the file, some data entries can be optionally omitted or removed from the file, leaving only the geometric outline and basic description of the component. Removal or distillation of the data or metadata of the file can be performed to remove irrelevant data amounts from the file for manufacturing, physical processing and / or release, and optionally save storage space. The tag can be unconditionally and permanently embedded in the component model number and cannot be easily removed without the risk of some undesirable side effects, including loss of certain functionality.

[0191] In a next step 13500, an additive manufacturing machine or facility, which may be partially or fully automated, may render the 3-D component model data as a physical component 13410. For example, the additive manufacturing machine or facility may include 3-D printing technology, such as selective laser melting or selective laser sintering. For example, the process may use a 3-D printer (e.g., Stratasys J750) or similar tool. The physical component may be formed from a variety of materials, including plastic, stainless steel, maraging steel, cobalt chromium, inconel, aluminum, gold, titanium, or other materials. The component may be made of one type of material (e.g., plastic). Alternatively, the component may be made of a composite material of two or more materials.

[0192] The presented physical component 13410 can correspond one-to-one with the 3-D component model data including the incorporated label. For example, a label can be physically formed (e.g., etched, printed, etc.) on the component while the component is being 3-D printed. Descriptive data encoded in the label can include, for example, a part number, a revision code, and a unique serial number. The unique correspondence between the label on the physical component and the label on the 3-D component model data can allow the label on the 3-D component model data to act as a reliable reference point throughout the life cycle of the component. For example, at each step of the component life cycle, the identity and revision level of the component are easily verified to ensure the correctness, source, and history of the component. Advantageously, the identification system can provide secure supply chain hygiene and a high degree of anti-counterfeiting credibility, which can improve the performance and reliability of the component and / or the final product produced by the component.

[0193] Identification systems can be used to track and monitor components throughout various stages of the component's life cycle. Specifically, identification systems can be used for configuration control and manufacturing assembly processes, such as assembly, sales, logistics, and revision control operations 13600. For example, a tag can be associated with an originating customer order number or a customer-defined order code. Customers who are sensitive to order-specific specifications and materials can use it to eliminate supply chain contamination from counterfeit or low-quality generic parts and prevent the risk of poor supply chain communication. In some cases, identification systems can be used for configuration management and pre-flight inspections for service life and reliability prediction 13700. For example, an assembly including multiple additively manufactured components can be inventoried, each of which is identified with a unique tag and verified simultaneously from a single point of view in a relatively short period of time (e.g., less than one second). This may be beneficial in reducing inventory time and improving the accuracy of comprehensive inventory records of hardware components. Inventory records are easily traceable, verifiable, and reliable.

[0194] In some cases, the life cycle of a component can be monitored, such as by tracking and verifying maintenance, failure, forensics, repair, reuse, and replacement manufacturing processes 13800. Records can drive reliability predictions and trigger preventive maintenance at specified intervals (e.g., mileage, time in use, stress history). Replacement components can be quickly and accurately specified when needed. The life cycle of a component can be accurately tracked, where reliability can be increased by tamper-proof identification markings on both the component and the 3-D data model. The overall reliability provided by the identification system can beneficially increase the value of used (e.g., refurbished) goods sold through one or more secondary channels and markets because the source information (e.g., design, materials, usage, life cycle) of the goods can be verified for each individual component.

[0195] In some cases, the identification system can allow tracking and verification of components 13900 for scrapping processes, including scrap disposal, insurance, reuse, scrapping, recycling, and environmental processes. For example, after a component reaches the end of its expected service life and is retired, it may be subjected to testing to estimate the additional or excess remaining service life it may still have. Components with some additional remaining service life may be discarded, such as to retain a safety margin, and discarding components with excess remaining service life may be wasteful. Components that are found to have some additional useful service life can be reused, for example, in applications that do not require high safety or applications with relatively low sensitivity to component failure. This can have economic value in the secondary (e.g., used parts) market and for insurance valuation of long-life vehicles with significant range history. The ability to track remaining service life is particularly useful and valuable for capital-intensive industrial and military equipment and platforms with long service lives. For processing and recycling, built-in tags can provide a verifiable and trustworthy link to manufacturing records, especially because accurate and specific material and chemical property records are required for environmental compatibility, metal recovery and other reuse applications.

[0196] In some cases, the label's geometric metadata can be used to locate the part of the component containing the label on its surface.

[0197] A data matrix label, such as an identification matrix, may contain one or more registration or alignment marks, such as within the border of the data matrix label, which may support accurate reading of the data matrix label. Fig.14AAn example of an identification matrix providing boundary markings is shown. For example, the identification matrix 14000 may include a first corner mark 14100, a second corner mark 14200, a third corner mark 14300, and a data area 14400. In some cases, three corner marks may depict and align the data area so that a sensor (e.g., a camera, a scanner, other imaging devices, etc.) may detect the identification matrix as an identification matrix and identify the data area. Alternatively or additionally, the corner marks may convey other non-symbolic information or metadata about the data area. Specifically, each corner mark or alternatively a combination of two or three of the corner marks may provide a position and / or orientation reference that transmits the position and attitude of the components containing the identification matrix in six dimensions, including X, Y, Z and pitch, roll, and yaw of the components relative to the workspace.

[0198] For example, corner markers 14100, 14200, and 14300 may be used to identify an identification matrix as a valid identification matrix and define the geometric position and viewing angle for an imaging device (e.g., a camera) of the identification matrix before the imaging device reads and decodes the data region 14400. Additionally, the corner markers may also identify the boundaries of a data region containing encoded data.

[0199] The identification matrix can be read by a sensor such as an imaging device. The imaging device can include one or more processors, and a memory having instructions executable by the one or more processors to read, decrypt, decode and / or otherwise process (e.g., determine the geometry) the identification matrix. Alternatively, another computing device can read, decrypt, decode and / or otherwise process the identification matrix. For example, built-in cyclic redundancy codes can be used to decode and verify the data in the identification matrix. One or more processors of the imaging device and / or another computing device can extract and locate the geometric position and orientation of the corner markers. Fig. 14B and Fig. 14C An example of geometric metadata extracted from an identification matrix is ​​shown. Fig. 14B shows the separation matrix, and Fig. 14C The same matrix on the surface of the component part is shown. For example, the geometric metadata of the matrix 14000 may include a reference XYZ coordinate angular position 14500 and a reference orientation vector 14600.

[0200] The XY (e.g., X, Y axis) positions of the matrix 14000 can be initially identified by a sensor reading the matrix and calculated as a coordinate frame (e.g., XY coordinates) of the reference sensor. For example, the XY coordinates can be initially identified as camera coordinates of the sensor reading the matrix. The camera coordinates can then be transformed into three-dimensional XYZ workspace coordinates using well-known geometric transformations.

[0201] The XYZ coordinates may include coordinate points in three axes (e.g., X, Y, Z axes). The reference XYZ coordinate angular position may include three-dimensional coordinates of a matrix position in three-dimensional space. Since the identification matrix may be designed to be located in a fixed position relative to the component, the matrix position may be referred to as a highly accurate reference code to locate the component in a workspace, such as in Figure 4 4105. Thus, the matrix can provide reference coordinates, which are useful for material handling, virtual fixturing, and other applications that require knowledge of the component in the workspace. For example, the reference coordinates can be used to guide one or more automated constructors and / or one or more mobile supply devices for robotic grasping, clamping, drilling, milling, surface finishing, and other manufacturing and processing processes.

[0202] In another aspect, the orientation of the matrix image 14000 can be determined by transforming the angles measured in the two-dimensional plane of the matrix surface, such as Fig. 14C The matrix image and the world position of the camera are sufficient to determine the position and orientation of the component in six dimensions: XYZ, pitch-roll-yaw. Fig.14D The changes in the roll and pitch angles in the identification matrix are shown. Using the direction vector 14600 as a reference, the matrix roll angle 14700 can be defined as the rotation angle around the azimuth vector 14600. The matrix pitch angle 14800 can be defined as the rotation angle around the matrix axis perpendicular to the pitch angle, where the axis lies in the matrix plane. Both angles can be measured simultaneously using a single sensor view of the matrix. For example, the roll and pitch orientation of the matrix can be extracted by measuring the perspective distortion. Since it can be known that the matrix has been manufactured in a precise rectangular form, it can be inferred that any deviation from straight line perfection is introduced by environmental deviations. These deviations can be quantitatively measured using well-known machine vision image analysis and pattern recognition techniques. Perspective distortion can be introduced primarily by changes in the orientation and attitude angles of component parts.

[0203] Fig.15A and Fig. 15B A rectangular solid portion 14010 is shown labeled using six data matrices (three visible in each figure), each matrix being located on two separate facets at two different poses. Fig.15A The rectangular solid portion is shown in a first posture. Fig. 15B The rectangular solid part is shown in a second posture. For example, the rectangular solid part can be additively manufactured (e.g., 3-D printed) to embed a unique matrix into each of its rectangular facets. When the rectangular part is resting on a flat surface, one of the matrices will face in an upward direction (e.g., Fig.15A Small plane 14011, Fig. 15BThis allows for quick visual identification of the pose of the component when viewed from above. Fig.15A 000a. In the first posture, facet 14011 faces upward and is marked with the first matrix 14000a. Facet 14012 faces forward and is marked with the second matrix 14000b, and facet 14013 faces right and is marked with the third matrix 14000c. The other three facets are not visible in the first posture. Above each visible matrix 14000a-c, an arrow identifies the reference orientation of the matrix. The orientation of the rectangular portion can be determined by looking at any one of the matrices, making additional information redundant in determining the orientation. Fig. 15B In the second posture, facet 14012 faces upward and is marked with the second matrix 14000b. Facet 14016 faces forward and is marked with the fourth matrix 14000d, and facet 14013 faces right and is marked with the third matrix 14000c. The other three facets are not visible in the second posture. Above each visible matrix 14000b-d, an arrow identifies the reference orientation of the matrix. The orientation of the rectangular portion can be determined by looking at either matrix, so that additional information will be redundant in determining the orientation. It can be determined by comparing the two Fig.15A and Fig. 15B To confirm, Fig. 15B Rotates in the upward direction Fig.15A The same rectangular portion of .

[0204] As seen in the above example, if the viewer (e.g., imaging device) has partial knowledge of another posture of the rectangular part, any geometric movement or rotation of the rectangular part 14010 can be inferred and accurately calculated from a single view of any one facet. In this way, the matrix can be used as a reference code that can identify the position and orientation of the component regardless of its posture. As long as the matrix is ​​visible and readable, there is no need to see any other part of the component. The above example describes a rectangular component with six faces and six natural postures or static positions on a flat surface. Components with less than or more than six static positions can be accommodated by appropriately marking one or more facets with a visible matrix. Not every aspect needs to be marked. As long as the matrix is ​​visible, the part can be recognizable in position and orientation. For example, a piece of paper may only need two matrices to be fully distinguished. Components with more facets or complex shapes may require a larger number of matrices. Alternatively, complex components can be accommodated by using additional imaging devices (e.g., cameras) in the workspace.

[0205] From the above examples, a method for identifying one or more assembly parts is provided. The method may include detecting the presence of one or more components, counting the number of visible components, classifying the visible components (e.g., serial number), locating the components (e.g., measuring position and / or orientation), and targeting processes (e.g., determining approach paths and grip points, etc.). For example, the position and / or orientation of the components may be used to guide a robot (such as an automated builder) to perform one or more processes.

[0206] Fig.16 An example of an accessory 16000 consisting of six component parts is shown. Each of the six components can be additively manufactured using a unique identification matrix included. The matrices 16001, 16002, 16003, 16004, 16005, and 16006 on each component can all be manufactured on the facets of their corresponding components. When the component parts are assembled together, the six matrices can all face approximately the same common direction, allowing all six independent matrices to be photographically read or photographed from one side of the component by an imaging device, such as in a single view and with a single illumination source. For example, a complete configuration inventory can be performed and completed by an imaging device with a single view and a single illumination source. In some cases, other facets of the six components may include similar matrices (e.g., visible from other viewing angles). The accessories and / or components of the components can be designed so that several facets of the component each include an identification matrix visible from different viewing angles, so that a complete configuration inventory of the accessory can be obtained from multiple or all sides of the accessory.

[0207] In some cases, the matrix can be used to identify the presence of an accessory or sub-assembly and locate its position and orientation. This technology can be used beneficially during material handling and assembly of systems or sub-systems. The matrix marking system can be used as a control basis to enable larger automation and robotic systems. The identification system can provide identification, geometric matrix data, tracking, pre-positioning and inventory of one or more components involved in one or more processes during one or more processes such as manufacturing, upgrading and repair.

[0208] Fig.17 An additively manufactured component 17000 is shown having two spatially distributed matrices 17100 and 17200. The two matrices may be permanently attached to the component and their positions may be stable relative to each other. When two or more matrices are visible on the component, because the XYZ position of each matrix on the component is known (e.g., from a 3-D model design of the component), each matrix may include geometric endpoints between which a defined line may be drawn. The position of the line in space may be identified with high precision and accuracy. Fig.18An arrangement with three spatially distributed matrices 18400, 18500, and 18600 is shown. A third matrix can be added to provide full dimensionality and additional precision. The three matrices define three lines, a first line 18100, a second line 18200, and a third line 18300, to form a triangle in a plane in three-dimensional space. With the plane containing the triangle, the system can identify the exact position and orientation of the components containing the three matrices.

[0209] The triangulation technique can provide additional self-checking capabilities by measuring errors corresponding to lengths and / or angles within a component, for example. When the cumulative error between the measured (e.g., empirical) and modeled (e.g., theoretical) matrix XYZ positions is small, the precision and / or accuracy of the position and orientation of the component can be considered high, and vice versa. For example, the empirical and theoretical lengths of each line between any two matrices can be compared to produce an error estimate. In some cases, theoretical measurements can be made on the CAD model. In another example, an orientation vector can be measured for each matrix, such as using the techniques disclosed above. Local distortion and errors can be calculated using the agreement or disagreement between matrix vector pairs between any two matrices. For example, in Fig.18 In Figure 1, all three matrices are shown to lie in a single plane, which indicates that theoretically all three orientation vectors of the three matrices should be parallel. However, matrix measurements taken from actual physical models may produce non-parallel orientation vectors. The difference between theoretical and empirical measurements can be used to estimate the variance of the physical component based on its computer model.

[0210] Deviations from empirical measurements (e.g., physical components) and theoretical predictions (e.g., computer models) may come from any number of causes, including measurement errors, miscalibration, lens aberrations, numerical calculation and conversion errors, environmental and / or systematic errors, and other effects (e.g., fraud). Precision-made model components can be used to test the reliability of sensor measurement systems. For example, a well-calibrated system may be expected to exhibit an error signature that spans a relatively modest operating range. Random error behavior contained within a relatively modest range may suggest that the system is operating properly. In another example, calibration drift or miscalibration can significantly and detectably increase the error range. An increase in error spread can beneficially provide useful early warnings and indications of system (e.g., sensor, 3-D printing) failures. For example, a sensor whose mounting point has been changed or shifted will introduce larger errors.

[0211] In some cases, the signature of the error profile of the counterfeit component can detect fraudulent or counterfeit components when compared to a precisely manufactured model component. For example, a common mistake made by counterfeiters may be poor geometric registration accuracy of distant features present on opposite sides of the counterfeit article. Fig.15A The location and orientation of the matrix 14000a-c of counterfeit articles may include a number of error symptoms. These symptoms may be used to detect and diagnose manufacturing defects, environmental or temperature changes or damage, and fraudulent or counterfeit parts.

[0212] In some cases, subtext encoding can be used to distinguish counterfeit products. Multiple matrices on a solid object can provide an anti-counterfeiting mechanism that enables rapid inspection and detection of fraudulent parts. Such a mechanism can be non-symbolic and non-numeric. Additive manufacturing can allow for minor adjustments to the dimensions of the matrix. One such dimension can be the XY displacement of the matrix on its flat printing plane. For example, in Fig.15A In the example, the position and orientation of the first matrix 14000a can be easily shifted within its printing plane without affecting the fit or function of the rectangular component. This shift can cause a disturbance in the line length of the inscribed measurement triangle, where Fig.18 It can be a triangle formed by matrices 14000a-c. For example, the intentionally introduced offset can intentionally extend the length of the line between two matrices 14000a and 14000b. The offset can be recorded in the computer model of the component and reflected in the manufactured component. Information about the offset can be hidden so that a counterfeiter may not or find it difficult to detect or measure the introduced offset. In some cases, different offsets can be introduced to other similar components, which may make it more difficult for a counterfeiter to understand the offset by inspecting one or more matrices on the component, even after inspecting a large number of similarly marked components. However, the specific offset may be obvious to sensors local to the system and can be detected, such as during a routing configuration scan of the component.

[0213] The technology can "hide" authentication data by encoding it between geometric metadata items, providing immediate verification to systems that know the geometric metadata and resistance to fraudulent systems that do not know the geometric data. This anti-counterfeiting mechanism can make it simple, fast and cheap for authorized users to detect fraudulent parts. It can establish cost and complexity barriers for counterfeiters, thereby deterring fraud associated with genuine manufactured products and replacement parts.

[0214] Fig.21 A diagram of an exemplary laser cutting process is shown. For example, the process can be Figure 2The laser cutting step 2200 process occurs in conjunction with the process. Automated constructors 2102 and 2104 are equipped with actuators 2100a and 2100b, respectively. Exemplary COTS carbon fiber panels are received from COTS receiving area 2209 or from COTS production area 2800 ( Figure 2 ) is provided to the laser cutting station 2200. The automated constructors 2102, 2104 may receive instructions and specifications for cutting the panel 2106 and may accordingly install (if not already installed) the actuators 2100a and 2100b for performing the cutting of the panel. The cut panels may then be provided to the chassis building line 2300 ( Figure 2 ) or another suitable location for further processing.

[0215] Fig. 22 A diagram of an exemplary automated process for assembling panels having nodes or extrusions is shown. For example, the process may occur in the vehicle body assembly area 2600, 2650 ( Figure 2 ), final assembly 2500 or another suitable location. Here, the automated constructors 2202, 2204 have equipped themselves with actuators for manipulating COTS carbon fiber panels 2206 to assemble and / or install panels with nodes or extrusions. In this illustration, the ends of the panels 2206 include extrusions 2208. The automated constructors 2202, 2204 collaborate to assemble the panels 2206 and insert the extrusions 2208 into the appropriate locations using machine learning, autonomous programs, or directions from a control station.

[0216] Fig.23 Shows something like Fig.21 Illustration of an exemplary laser cutting process performed at an assembly station. Fig.23 Panels 2310a, 2310b on an assembly line that are processed by automated constructors 2302, 2304, 2306, 2308 may be included. In an exemplary embodiment, panels 2310a, 2310b are transported on a moving assembly line, and the laser cutting process occurs as the panel segments are transported. In other embodiments, panels 2310a, 2310b may arrive at the station via a mobile vehicle, an automated constructor, manually, or by other means.

[0217] Fig.24 A diagram of an exemplary process for performing adhesive application at an assembly station is shown. Fig.24 It is possible to build the chassis line 2300 ( Figure 2) is an example of a function performed at . Automated constructors 2402, 2404, 2406, 2408, and 2412 apply adhesive to carbon sheet 2410 for building nodes and assembling other components. For example, a division of labor between automated constructors may be involved, such that some automated constructors have actuators equipped to move and manipulate carbon sheets, and other automated constructors have actuators equipped to apply adhesive. In other embodiments, carbon sheets or other materials can be moved on an automated assembly line. In an exemplary embodiment, the entire process can be automatic.

[0218] Fig.25 A diagram of an exemplary process for combining and assembling extrusions to a node performed by multiple collaborative automated constructors is shown. A node, node assembly, or node network 2516 is located at a station where automated constructors 2502, 2508, 2510, and 2512 apply extrusions to node 2516. For example, automated constructor 2512 is equipped with an actuator for assembling extrusion 2520 to section 2518 of node 2516. Automated constructors 2504, 2506 may then sequentially apply panels 2522 or other components after assembling the extrusions. The process may be performed as part of chassis build 2300, final assembly 2500, or other suitable area or station ( Figure 2 ) occurs as part of the

[0219] Fig.26 2604, 2606, 2608 for assembling a vehicle suspension to a chassis. For example, the process may be performed in chassis build line 2300, final assembly 2500, body assembly 2600, 2650, or another suitable area ( Figure 2 ) to perform the process. Fig.26 As will be appreciated, multiple automated constructors collaborate to assemble the suspension system (partially obscured from view) onto chassis 2620.

[0220] Fig. 27 2702 is a diagram of an exemplary process performed by multiple automated constructors 2706, 2708, 2710 in the process of landing the vehicle body 2702 on the chassis 2704. For example, the process may occur in the final assembly 2500 ( Figure 2 ). In this illustration, automated constructors 2706, 2710 are equipped with tools or actuators for processing vehicle body 2702 for insertion onto chassis 2704. Depending on the embodiment, this process may be partially or fully automated.

[0221] The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. It will be apparent to those skilled in the art that various modifications to these exemplary embodiments presented throughout this disclosure will be apparent, and the concepts disclosed herein can be applied to other technologies for 3-D printing of components for transport structures. Therefore, the claims are not intended to be limited to the exemplary embodiments presented throughout this disclosure, but to be given the full scope consistent with the language claims. All structural and functional equivalents of the elements of the exemplary embodiments described throughout this disclosure that are known or will be known to those of ordinary skill in the art are intended to be covered by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public, regardless of whether these disclosures are explicitly stated in the claims. Unless the phrase "device for..." is used to expressly state the elements, or the phrase "step for..." is used to expressly state the elements in the case of method claims, the claim elements shall not be interpreted according to the provisions of 35 U.S.C. §112 (f) or similar laws in the applicable jurisdiction.

Claims

1. A method for automatically assembling a transport structure by an automated assembly system, the automated assembly system comprising a 3-D printer, a first automated constructor positioned at a first robotic assembly station, and a second automated constructor configured to travel to and from the first robotic assembly station, wherein: The method further comprises: controlling the 3-D printer to print at least a portion of a component of the transport structure; controlling the second automated constructor to transfer the component to the first robotic assembly station such that a base of the second automated constructor moves relative to an underlying surface; and During assembly of the transport structure, the first automated constructor is controlled to install the component.

2. The method according to claim 1, wherein At least the 3-D printer or one of the plurality of automated constructors comprises one or more sensors, the one or more sensors being configured to enable at least the first automated constructor or the second automated constructor, respectively, to adaptively perform one or more machine learning functions, the method further comprising: The one or more machine learning functions are performed.

3. The method according to claim 2, wherein Performing the one or more machine learning functions includes at least optimizing a print movement pattern, enabling motion control of a print head, fly-by-flight printing for material development, structure optimization, or automatically accepting a tool for vehicle assembly.

4. The method according to claim 1, wherein The 3-D printer includes an automated robotic device having a robotic arm having a robotic actuator at a distal end of the arm, the method further comprising: The robotic arm is controlled to transfer the component to the second automated constructor.

5. The method according to claim 1, wherein The second automated constructor includes an automated robotic device having a robotic arm having a robotic actuator at a distal end of the arm, wherein: Transferring the component to the first robotic assembly station further comprises: The robotic arm is controlled to transfer the component to the first robotic assembly station.

6. The method according to claim 1, wherein The automated assembly system further comprises a plurality of robotic assembly stations, and the method further comprises: The second automated constructor is controlled to travel to and from each of the plurality of robotic assembly stations during assembly of the transport structure.

7. The method according to claim 6, further comprising: During assembly of the transport structure, the 3-D printer is controlled to travel to and from two or more of the robotic assembly stations.

8. The method according to claim 1, wherein The first automated constructor includes an automated robotic device having a robotic arm having a robotic actuator at a distal end of the arm, wherein: Controlling the first automation constructor to install the component further includes: During assembly of the transport structure, the robotic arm is controlled to install the component.

9. The method according to claim 8, further comprising: During assembly of the transport structure, the first automated constructor is controlled to exchange the robotic arm with another robotic arm.

10. The method according to claim 8, further comprising: During assembly of the transport structure, the first automated constructor is controlled to exchange the robotic effector with another robotic effector.

11. The method according to claim 1, wherein Controlling the 3-D printer to print at least a portion of the components of the transport structure further comprises: The 3-D printer is controlled to print a first portion of the component onto an unprinted second portion of the component.

12. The method according to claim 1, wherein Controlling the 3-D printer to print at least a portion of the components of the transport structure further comprises: The 3-D printer is controlled to print an interconnect configured to interconnect the component to another structure.

13. The method according to claim 1, wherein The underlying surface includes a floor, and controlling the second automated constructor to transfer the component to the first robotic assembly station further includes: The second automated constructor is controlled to move so that the base moves relative to the floor.

14. The method according to claim 13, wherein The base of the second automated builder includes wheels configured to roll on the floor, and controlling the second automated builder to transfer the component to the first robotic assembly station further includes: The wheels are controlled to roll on the floor.

15. The method according to claim 1, wherein Controlling the second automated constructor to transfer the component to the first robotic assembly station further comprises: The second automated constructor is controlled to simultaneously transfer a plurality of components to the first robotic assembly station.

16. The method according to claim 15, wherein The second automated constructor is configured to carry a structure having the plurality of components arranged thereon, and controlling the second automated constructor to transfer the components to the first robotic assembly station further comprises: The second automation constructor is controlled to carry the structure.

17. The method according to claim 16, wherein The structure on which the plurality of components are arranged includes a tray.

18. The method according to claim 1, wherein Controlling the second automated constructor to transfer the component to the first robotic assembly station further comprises: The second automation constructor is controlled to provide the component directly to the first automation constructor.

19. The method according to claim 1, wherein The automated assembly system includes a plurality of 3-D printers, each of the 3-D printers being configured to print components of the transport structure, the method further comprising: The second automated constructor is controlled to collect the 3-D printing components from the plurality of 3-D printers.

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