Partially assembled vehicle that autonomously completes its own assembly and method for manufacturing the vehicle

Abstract

A partially assembled vehicle that autonomously completes its own assembly, including a chassis, wheels rotatably coupled to the chassis, a drive system mounted on the chassis and operatively communicating with the wheels, a navigation system, a central platform controller, and a position determination system. A safety sensor guidance system and a controller circuit are added, and the controller circuit is programmed to temporarily take over the central platform controller in response to an external fleet control. The temporary takeover includes the steps of: identifying a plurality of assembly stations that the partially assembled vehicle must access to complete its own assembly; constructing a sequence for accessing each of the plurality of assembly stations; and, in response to sensor inputs from the safety sensor guidance system, commanding the drive system to propel and steer the partially assembled vehicle to pass through the sequence of the plurality of assembly stations.

Description

Technical Field

[0001] The present disclosure generally relates to the manufacture of vehicles and, more particularly, to partially assembled vehicles that autonomously complete their own assembly. Background Art

[0002] Available vehicle manufacturing methods typically rely on fixed assembly lines with conveyors. The fixed assembly line conveyors perform a fixed sequence of assembly steps; this hinders the optimal use of assembly stations. Additionally, when a fixed assembly line conveyor fails, it affects all vehicles attached to it.

[0003] In addition to solving related problems, the following disclosure also provides technical solutions to these technical problems. Further, other desirable features and characteristics of the systems and methods will become apparent from the following detailed description and the appended claims in conjunction with the accompanying drawings and the prior background. Summary of the Invention

[0004] The provided embodiment is a partially assembled vehicle that autonomously transports itself through its own assembly process, the partially assembled vehicle comprising:

[0005] A chassis and wheels, the wheels being rotatably coupled to the chassis; a drive system mounted on the chassis and operatively in communication with the wheels, and further including on-vehicle and operatively communicating with each other: a navigation system, a central platform controller, and a position determination system; a safety sensor guidance system mounted on-vehicle to the chassis, the safety sensor guidance system including sensors, transceivers, and an emergency stop (estop) device; and a controller circuit operatively coupled to the central platform controller and the safety sensor guidance system, the controller circuit being programmed to: in response to receiving a start data packet, begin a temporary takeover of the central platform controller, the temporary takeover including the steps of: activating the transceiver to continuously communicate with an external fleet control source; identifying a plurality of assembly stations that the partially assembled vehicle must access to complete its own assembly; constructing a sequence for accessing each of the plurality of assembly stations; in response to sensor data from the safety sensor guidance system, commanding the drive system to propel, brake, and steer the partially assembled vehicle through the sequence of the plurality of assembly stations; when the partially assembled vehicle is at each assembly station in the sequence, determining that the assembly associated with the assembly station is complete after passing the respective in-station diagnostic test; wherein commanding the drive system further has the function of determining that the current assembly station has completed the assembly associated with the current assembly station; modifying or interrupting the instruction for the drive system of the partially assembled vehicle to pass through the sequence in response to a repair data packet received from the external fleet control source; preventing the drive system from operating in response to detecting activation of the estop device; after determining that the partially assembled vehicle has completed the sequence, determining that the partially assembled vehicle has autonomously completed its own assembly; and terminating the temporary takeover after determining that the partially assembled vehicle has autonomously completed its own assembly; and issuing a prompt to the external fleet control source when determining that the partially assembled vehicle has autonomously completed its own assembly.

[0006] In one embodiment, the controller circuit is further programmed to perform the following steps: when the partially assembled vehicle is at an assembly station among the plurality of assembly stations (the partially assembled vehicle accesses the assembly station to complete its own assembly), determining that the assembly associated with the assembly station is incomplete when the corresponding in-station diagnostic test fails; issuing a prompt of incomplete assembly to the external fleet control source; and wherein commanding the drive system further has the function of routing instructions in response to the incomplete assembly.

[0007] In an embodiment, the start data packet identifies the model and configuration information of the partially assembled vehicle, and wherein the controller circuit is further programmed to generate the sequence based on the model and configuration information.

[0008] In an embodiment, beginning the temporary takeover of the central platform controller includes installing a temporary program into the central platform controller, and wherein the controller circuit is further programmed to: after prompting the external fleet control source that the partially assembled vehicle has autonomously completed its own assembly, remove the temporary program.

[0009] In an embodiment, the temporary program includes instructions that override the power distribution in a partially assembled vehicle and instructions that control the functionality of propulsion, braking, and steering.

[0010] In one embodiment, the sequence is one of a plurality of potential sequences, wherein each of a plurality of assembly stations is accessed, and wherein the controller circuitry is further programmed to: receive a status indicator from each of the plurality of assembly stations; and construct the sequence based on the received status indicators.

[0011] In an embodiment, the safety sensor guidance system further includes a path projector configured to project a visible light beam forward from the center of the partially assembled vehicle.

[0012] In an embodiment, the sensor in the safety sensor guidance system is a first sensor attached to a first corner of the chassis, and wherein the safety sensor guidance system further includes a second sensor attached to a second corner of the chassis.

[0013] In one embodiment, the first sensor and the second sensor are each configured to detect an intrusion within a predetermined range from the respective sensor.

[0014] In one embodiment, the predetermined range is less than two feet, but will in practice be defined by accepted standards for safety-rated sensing and stopping distances.

[0015] One embodiment provides a method for a partially assembled vehicle to autonomously transport itself through an entire process to complete its own assembly. The method includes: constructing a partially assembled vehicle, the partially assembled vehicle including a chassis and wheels rotatably coupled to the chassis, a drive system mounted on the chassis and operatively connected to the wheels, and on the partially assembled vehicle and operatively connected to each other: a navigation system, a central platform controller, and a position determination system; installing a safety sensor guidance system on the chassis, the safety sensor guidance system including sensors, transceivers, and an emergency stop (estop) device; and at a controller circuit, the controller circuit being operatively coupled to the central platform controller and the safety sensor guidance system, performing the following steps: receiving a start data packet from an external fleet control source; starting a temporary takeover of the central platform controller, the temporary takeover including the steps of: activating the transceiver to continuously communicate with the external fleet control source; identifying a plurality of assembly stations that the partially assembled vehicle must access to complete its own assembly; constructing a sequence for accessing each of the plurality of assembly stations; in response to sensor data from the safety sensor guidance system, commanding the drive system to propel and steer the partially assembled vehicle through the sequence of the plurality of assembly stations; when the partially assembled vehicle is at each assembly station in the sequence, determining that the assembly associated with the assembly station is completed after passing the respective in-station diagnostic test; wherein commanding the drive system further has the function of determining that the current assembly station has completed the assembly associated with the current assembly station; modifying or interrupting the instruction for the drive system of the partially assembled vehicle to pass through the sequence in response to a maintenance data packet received from the external fleet control source; preventing the drive system from operating in response to detecting the activation of the emergency stop device; and terminating the temporary takeover after determining that the partially assembled vehicle has autonomously completed its own assembly; and issuing a prompt to the external fleet control source when determining that the partially assembled vehicle has autonomously completed its own assembly.

[0016] In an embodiment, when the partially assembled vehicle is at each assembly station in the sequence, it is determined that the assembly associated with the assembly station is incomplete when the corresponding in-station diagnostic test fails; the external fleet control source is prompted with an incomplete status; and wherein commanding the drive system further has the function of routing instructions in response to the incomplete status.

[0017] In an embodiment, the start data packet identifies the model and configuration information of the partially assembled vehicle and further includes generating a sequence based on the model and configuration information.

[0018] In an embodiment, starting the temporary takeover of the central platform controller includes installing a temporary program into the central platform controller and further includes removing the temporary program after prompting the external fleet control source that the partially assembled vehicle has autonomously completed its own assembly.

[0019] In an embodiment, the temporary program includes instructions that override the power distribution in a partially assembled vehicle and instructions that control the functionality of propulsion and steering.

[0020] In one embodiment, the sequence is one of a plurality of potential sequences, where each of a plurality of assembly stations is accessed and further includes receiving a status indicator from each of the plurality of assembly stations; and constructing the sequence based on the received status indicators.

[0021] In an embodiment, the sensor in the safety sensor guidance system is a first sensor attached to a first corner of the chassis, and where the safety sensor guidance system further includes a second sensor attached to a second corner of the chassis.

[0022] Embodiments of a safety sensor guidance system for temporary use on a partially assembled vehicle are provided, the partially assembled vehicle that autonomously transports itself throughout and completes its own assembly. The safety sensor guidance system includes: an auxiliary navigation sensor; a sensor configured to detect intrusion within a predetermined range; an emergency stop device; and a communication structure operatively communicating with the auxiliary navigation sensor, the sensor, and the emergency stop device, the communication structure configured to receive a start data packet from an external source and, in response to the start data packet, initiate a temporary takeover of a central platform controller, including the steps of: commanding a drive system to advance and steer the partially assembled vehicle through a sequence of a plurality of assembly stations; when the partially assembled vehicle is at each assembly station in the sequence, receiving a determination result from the central platform controller, specifically a determination that the assembly associated with the assembly station has been completed upon passing a corresponding in-station diagnostic test; further commanding the drive system based on the determination result of the current assembly station, i.e., that the assembly associated with the current assembly station has been completed; modifying or interrupting the command for the drive system of the partially assembled vehicle through the sequence in response to receiving a repair data packet from an external source; preventing the drive system from operating in response to detecting activation of the emergency stop device; determining that the partially assembled vehicle has autonomously completed its own assembly after determining that the partially assembled vehicle has completed the sequence; and terminating the temporary takeover after determining that the partially assembled vehicle has autonomously completed its own assembly.

[0023] In an embodiment, one or more visual cue devices are further included, the one or more visual cue devices operatively communicating with the communication structure and configured to visually represent the various states of the system of the partially assembled vehicle.

[0024] In an embodiment, a support structure is further included, the support structure configured to enclose at least a portion of the partially assembled vehicle and attach to that portion, with the remaining components of the safety sensor guidance system attached to the support structure. Description of the Drawings

[0025] Exemplary embodiments will be described below in conjunction with the following drawings, wherein like numerals represent like elements, and wherein:

[0026] Figure 1 is a schematic diagram showing a partially assembled vehicle autonomously completing its own assembly according to various embodiments;

[0027] Figure 2 is a simplified top-down view showing a partially assembled vehicle and a plurality of assembly stations that the partially assembled vehicle visits to complete its assembly according to various embodiments;

[0028] Figure 3 is a flow chart depicting an exemplary method for a partially assembled vehicle to autonomously complete its own assembly according to various embodiments; and

[0029] Figure 4 is a schematic diagram illustrating a safety sensor guidance system temporarily used on a partially assembled vehicle, wherein the partially assembled vehicle is configured to complete its own assembly, according to various embodiments. DETAILED DESCRIPTION

[0030] The following detailed description is merely exemplary in nature and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.

[0031] Embodiments of the present invention may be described herein in terms of functional and / or logical block components and various processing steps. It should be appreciated that these block components may be implemented by any number of hardware, software, and / or firmware components configured to perform the specified functions. For example, embodiments of the present disclosure may employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, etc., which may perform various functions under the control of one or more microprocessors and other control devices.

[0032] As used herein, the term "module" may refer to any hardware, software, firmware, electronic control component, processing logic, and / or processor device that, alone or in any combination, provides the functionality attributed to the module. In various embodiments, the module includes one or more of the following: an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), an electronic circuit, a computer system including a processor (shared, dedicated, or group) and a memory that executes one or more software or firmware programs, a combinational logic circuit, and / or other suitable components that provide the functionality attributed to the module.

[0033] For the sake of brevity, conventional techniques related to signal processing, data transmission, signal transmission, control, machine learning models, radar, lidar, image analysis, and other functional aspects of the system (and its various operating components) may not be described in detail herein. Additionally, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and / or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in the embodiments of the present disclosure.

[0034] As mentioned, available vehicle manufacturing methods typically rely on a fixed assembly line with conveyors. The fixed assembly line conveyor performs a fixed sequence of assembly steps; this hinders the optimal use of the assembly stations. Additionally, when the fixed assembly line conveyor fails, it affects all the vehicles attached to it.

[0035] Exemplary embodiments provide a technical solution to this problem in the form of a partially assembled vehicle 100 that autonomously transports itself throughout its own assembly process (hereinafter abbreviated as the partially assembled vehicle 100), as Figure 1 shown. As used herein, autonomous means without further human input or guidance. As will be described in more detail below, the provided partially assembled vehicle 100 is autonomous (self-guided and self-powered), which allows the vehicle tires (wheels 20) to be placed on the assembly plant floor rather than on a conveyor system. The provided partially assembled vehicle 100 communicates continuously, either wired or wirelessly, with a fleet management department and can (during a temporary takeover) temporarily repurpose various on-vehicle ECM modules with a manufacturing professional software protocol to accept commands for ranging, deceleration, acceleration, operator sensing, and safety protocols. The provided partially assembled vehicle 100 utilizes the existing on-vehicle power management infrastructure to route power to the drive system 106 and control safety during assembly. The provided partially assembled vehicle 100 can perform in-station testing and diagnostics, utilize the fleet management system for in-station calibration, or request that the vehicle be rerouted to a repair area.

[0036] An embodiment of the partially assembled vehicle 100 includes a chassis 101 and wheels 20, each of the chassis 101 and the wheels 20 being rotatably coupled to the chassis 101 near respective corners of the chassis. The partially assembled vehicle 100 is depicted as having four wheels 20, but in other embodiments, the number of wheels 20 may vary. The partially assembled vehicle 100 includes at least a set of functional blocks, a drive system 106, which generally includes known vehicle systems for vehicle operation, such as a propulsion system, a transmission system, a steering system, actuators for the wheels, and a braking system, and the drive system 106 generally generates various signals, including vehicle speed and vehicle acceleration. In various embodiments, the drive system 106 is operably coupled to one or more on-vehicle components and systems via a communication bus 130. In the illustrated embodiment, the partially assembled vehicle 100 is depicted as a passenger vehicle, but other vehicle types may also be used, including motorcycles, taxis, fleets, buses, sedans, vans, trucks, sport utility vehicles, other automobiles, recreational vehicles (RVs), locomotives, logistics transporters, drones, and other vehicles. When its assembly is complete, the partially assembled vehicle 100 may be an autonomous vehicle or a semi-autonomous vehicle.

[0037] Various embodiments of the partially assembled vehicle 100 may include one or more other components and / or on-vehicle systems that generally communicate with each other via the communication bus 130. Non-limiting examples of on-vehicle components that communicate via the communication bus 130 include the drive system 106, a central platform controller 108, a transceiver 112, a global and / or local position determination system 116, and other forms of navigation systems that use cameras, scanners, or sense the environment around the vehicle 120. Various embodiments of the partially assembled vehicle 100 also include a controller circuit 104 and a safety sensor guidance system 110. The functions and operations of each of these components are described in more detail below.

[0038] The controller circuit 104 manages the communication between the partially assembled vehicle 100 and an external source 150. In the environment around the partially assembled vehicle 100, the external source 150 includes one or more external fleet controllers and assembly station controllers located outside the partially assembled vehicle 100.

[0039] The transceiver 112 may be configured to enable communication between in-vehicle components and systems and various external sources 150 (such as cloud server systems). Thus, in various embodiments, the transceiver 112 includes hardware and software to support one or more communication protocols for wireless communication 151 (such as Wi-Fi and Bluetooth) between the controller circuit 104 and external sources (such as routers, the Internet, clouds, satellites, communication towers, and ground stations). The transceiver 112 may also be adapted for wired communication and support one or more input ports. In various embodiments, the transceiver 112 may be integrated within the central platform controller, integrated within another in-vehicle control module, and non-integrated, with at least one functional portion located on the safety sensor guidance system 110.

[0040] The position determination system 116 may be a global positioning system known in the mobile platform industry and / or local position determination systems, and the system 116 is designed to operate within a facility. The position determination system 116 may interact via the transceiver 112 and various external sources to provide information about the position of the vehicle in three-dimensional space at any given time.

[0041] The navigation system 120 may obtain and process signals from various in-vehicle components to make determinations about the current position, trajectory, speed, acceleration, etc., and cooperate with the central platform controller 108 and the position determination system 116 to plan future positions, trajectories, speeds, accelerations, turns, etc.

[0042] In various embodiments, the central platform controller 108 is configured to receive and integrate communications from modules and systems on the partially assembled vehicle 100. Thus, the central platform controller 108 may manage the operations of the drive system 106, the global positioning system (position determination system 116), and the navigation system 120, as well as manage communications from in-vehicle external sources (such as from the external source 150 via the transceiver 112).

[0043] In various embodiments, the central platform controller 108 is configured to manage and distribute power on the partially assembled vehicle 100, which may be via a separate power management module and battery, or have a power management module and battery integrated within the central platform controller.

[0044] As described in more detail below, the partially assembled vehicle 100 autonomously completes its own assembly, which is understood to imply that various additional modules and systems will be integrated or installed on the partially assembled vehicle 100. Thus, the central platform controller 108 is configured to accommodate each newly assembled component and integrate various additional vehicle components, such as adding at one or more assembly stations (see Figure 2)。Non-limiting examples of vehicle components and activities that can be added at various assembly stations include: adding metal to form the vehicle body, painting the vehicle, installing HVAC, completing drive system components, installing additional adornments, installing a user interface configured to provide any combination of touch, voice / audio, cursor, button press, and gesture control; attaching a mapping system that includes a database for storing up-to-date and high-resolution maps of streets and environmental features; attaching an additional camera system, etc.

[0045] Embodiments of the partially assembled vehicle 100 may include a safety sensor guidance system 110 and a controller circuit 104. The safety sensor guidance system 110 may be mounted to the chassis 101. In an embodiment, the safety sensor guidance system 110 includes sensors 114, a transceiver 112, and an emergency stop (estop) device 118. In various embodiments, the sensors 114 are configured to detect intrusions within a predetermined range 130 measured outward from the respective sensor. In various embodiments, the predetermined range is less than two feet, but in practice will be defined by accepted standards for safety-rated sensing and stopping distances. In some embodiments, the safety sensor guidance system 110 further includes a path projector 122 configured to project a visible beam forward from the partially assembled vehicle 100. In some embodiments of the safety sensor guidance system 110, multiple sensors 114 are attached at one or more different corners of the chassis. For example, a sensor 114 in the safety sensor guidance system 110 may be a first sensor attached to the first corner of the chassis, and wherein the safety sensor guidance system 110 further includes a second sensor (124) attached to the second corner of the chassis, a third sensor (126) attached to the third corner of the chassis, and a fourth sensor (128) attached to the fourth corner of the chassis. Each sensor 114 may be configured to sense a three-dimensional volume 132 such that the volumes 132 overlap to create a buffer zone around the chassis.

[0046] Reference Figure 4 , some embodiments of the safety sensor guidance system 110 include transceiver 112 functionality and a communication structure 402 (wired or wireless) specifically configured to manage communication (via 151) between the central platform controller 108 and various external sources 150.

[0047] In embodiments having a communication structure 402, it may be configured to receive a start packet from an external source 150 and temporarily take over the central platform controller 108 in response to the packet. Additionally, in embodiments having a communication structure 402, it may be configured to receive data and instructions at each assembly station and transmit the status back to various external sources 150.

[0048] Some embodiments of the safety sensor guidance system 110 also include an auxiliary navigation sensor 406, which is only configured for navigation operations across the entire manufacturing floor. In some embodiments, the components of the safety sensor guidance system 110 are each attached to a rigid support structure 408, which can be easily attached to the chassis. Although Figure 4 the partially assembled vehicle 100 shown depicts the safety sensor guidance system 110 only on the front of the vehicle, in other embodiments, the components shown in structure 4 can be mirrored and placed on the rear of the vehicle 100.

[0049] In some embodiments, the safety sensor guidance system 110 also includes one or more visual cue devices 404. Non-limiting examples of visual cue devices 404 include LED systems, which are configured to emit light of different colors to convey status; for example, green indicates "no problem", yellow indicates a reminder, and red indicates a warning, including a time flashing mode, to alert the operator's attention. In some embodiments, multiple visual cue devices 404 are included in the safety sensor guidance system 110, and each of the multiple visual cue devices 404 is assigned to a different system or operating status, for example, one for the battery charge level, one for displaying the operating mode, etc.

[0050] Returning the focus to the partially assembled vehicle 100, the operations performed by the partially assembled vehicle 100 can be centrally managed. In Figure 1 this case, the central management of tasks / operations is provided by the controller circuit 104. In other embodiments, the central management of tasks / operations can be generated by a controller module, PLA, custom circuit, etc. In various embodiments, the controller circuit 104 is communicatively coupled to in-vehicle systems and components, particularly the central platform controller 108, via a communication bus 130. The controller circuit 104 and / or the central platform controller 108 are each configured to transmit commands, control, and power for various in-vehicle systems and components via the communication bus 130. The controller circuit 104 is programmed to override the power management and management performed by the central platform controller 108 during the operation (assembly) of the partially assembled vehicle 100.

[0051] In Figure 1In the various embodiments shown, the controller circuit 104 is implemented as an enhanced computer system that includes a computer-readable storage device or medium, a memory 54 for storing instructions, algorithms, and / or programs 56, and operating parameters 58, such as pre-programmed models and configuration requirements. The controller circuit 104 also includes a processor 50 for executing the program 56 and an input / output interface (I / O) 52. The computer-readable storage device or medium, the memory 54 may include volatile and non-volatile storage devices such as read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operating variables when the processor 50 is powered off. The memory 54 can be implemented using any of several known memory devices, such as PROM (programmable read-only memory), EPROM (electrically programmable read-only memory), EEPROM (electrically erasable programmable read-only memory), flash memory, or any other electrical, magnetic, optical, or combination memory device capable of storing data that is used by the processor 50 to control the vehicle 100, some of which represents executable instructions. In various embodiments, the processor 50 is configured to implement the system 102. The memory 54 can also be used by the processor 50 to cache data, temporarily store the results of comparisons and analyses, and the like. During the initialization or installation operation of the method, the information in the memory 54 can be sourced and / or imported from an external source; it can also be programmed through the user I / O interface.

[0052] The input / output interface (I / O) 52 is operably coupled to the processor 50 via a bus and enables in-circuit 104 communication as well as out-of-circuit 104 communication. The input / output interface (I / O) 52 may include one or more wired and / or wireless network interfaces and can be implemented using any suitable method and device. In various embodiments, the input / output interface (I / O) 52 includes hardware and software to support one or more communication protocols for wireless communication between the processor 50 and external sources (such as satellites, clouds, communication towers, and ground stations). In various embodiments, the input / output interface (I / O) 52 supports communication with technicians and / or communication with one or more storage interfaces for directly connecting to storage devices.

[0053] During operation of the partially assembled vehicle 100, the processor 50 loads and executes one or more algorithms, instructions, and rules embodied as the program 56 and thus controls the general operation of the system 102. During operation of the system 102, the processor 50 may receive data from the communication bus 130 or an external source 150. In various embodiments of the system 102, the controller circuit 104 may: perform operations attributed to the system 102 according to an algorithm; perform operations according to state machine logic; and perform operations according to the logic in a programmable logic array.

[0054] While an exemplary embodiment of the partially assembled vehicle 100 has been described in the context of the controller circuit 104 being implemented as a fully operational enhanced computer system, those skilled in the art will recognize that the mechanisms of the present disclosure can be distributed as a program product including a program 56 and predefined parameters. Such a program product can include an arrangement of instructions organized into multiple interdependent program code modules, each program code module being configured to implement separate processes and / or perform separate algorithmic operations and further being arranged to manage the data flow through the system 102. The program code modules can each include an ordered list of executable instructions for implementing the logical functions of the processes executed by the system 102. The instructions in the program code modules, when executed by a processor (e.g., processor 50), cause the processor to receive and process signals and perform the logic, computations, methods, and / or algorithms described herein to autonomously and in real time perform vehicle-target localization and generate associated commands.

[0055] Once developed, the program code modules that make up the program product can be stored and distributed individually or together using one or more types of non-transitory computer-readable signal-bearing media (e.g., non-transitory computer-readable media), which can be used to store and distribute instructions. Such a program product can take various forms, and the present disclosure applies equally regardless of the type of computer-readable signal-bearing media used for the distribution. Examples of signal-bearing media include recordable media such as floppy disks, hard disk drives, memory cards, and optical discs, as well as transmission media such as digital and analog communication links. It should be understood that in certain embodiments, cloud-based storage and / or other technologies can also be used as the memory and the program product for viewing license requests based on time.

[0056] Figure 2 FIG. 200 is a simplified top-down view showing the partially assembled vehicle 100 and a plurality of assembly stations, where the partially assembled vehicle 100 accesses these assembly stations to complete its own assembly; in the example, the plurality refers to seven assembly stations (1-7). The sequence is the sequence of assembly stations, arranged in a time series. The sequence is indicated by the line 208 connecting the assembly stations, and the indicated sequence is: 1, 2, 3, 7, 6, 5, 4.

[0057] The construction of the sequence for accessing each of the multiple assembly stations can be affected by one or more factors, such as: the shortest distance between the assembly stations, the availability of parts / vehicle components at the assembly stations, the queue of other partially assembled vehicles at a given assembly station, component dependencies, etc. In one embodiment, the sequence is one of multiple potential sequences, where each of the multiple assembly stations is accessed, and where the controller circuit 104 is further programmed to: receive respective status indicators from each of the multiple assembly stations; and construct the sequence based on the received status indicators.

[0058] Once the sequence is constructed, the controller circuit 104 commands the drive system 106 to propel and steer (e.g., via path 208) the partially assembled vehicle 100 through the sequence of multiple assembly stations. The commands for propulsion and steering can be further adjusted by, or correspond to, a safety situation detected by sensors in the safety sensor guidance system 110. For example, when sensor data from the safety sensor guidance system 110 indicates that an object or person is obstructing the vehicle, the controller circuit 104 will, in response thereto, command the drive system 106 to temporarily stop propulsion and steering until the safety situation is resolved, or use it in combination with the navigation system to advance safely on a path that allows the vehicle to move forward while maintaining a safe distance.

[0059] At each assembly station, the assembly associated with the assembly station is performed. For example, the installation of a camera system, or the installation of a user interface device, uploading high-definition map data, etc. This assembly can be triggered by the partially assembled vehicle 100 reaching the assembly station. The assembly can be performed by an external device, an external system (such as a robot), or a person. Upon detecting the completion of the assembly, the controller circuit 104 runs respective in-station diagnostics (tests) to determine whether the assembly has passed (successfully) or failed. In some embodiments, the step of running in-station diagnostics may include first receiving instructions from an external fleet control. In other embodiments, the step of running in-station diagnostics may include receiving in-station diagnostic tests by temporarily communicating with sources at each assembly station. In other embodiments, the step of running in-station diagnostic tests may be entirely managed by the program 56 loaded in the controller circuit 104.

[0060] As can be appreciated, the steps of the command-driven system are notified by the pass / fail status at each assembly station. For example, when passing through the current assembly station, the steps of the command-driven system advance autonomously to propel and steer the partially assembled vehicle 100 to the next assembly station in the sequence. However, in response to a failure at an assembly station, the controller circuit 104 can modify or interrupt the sequence, such as advancing to a repair station 202. This scenario is illustrated by the dashed line 206 from assembly station 7. In various embodiments, in response to receiving a repair data packet from an external fleet control source 150, the controller circuit 104 can also modify or interrupt the commands for the drive system of the partially assembled vehicle 100 to pass through the sequence. For example, the external fleet control source 150 can override the constructed sequence to force the imposition of a different sequence, and in response to that different sequence, the controller circuit 104 can modify or interrupt the commands for the drive system of the partially assembled vehicle 100 to travel through a different sequence. In another example, the external fleet control source 150 can override the constructed sequence to bring the partially assembled vehicle 100 to a designated repair station. An example of this scenario can include swapping out an older version of a vehicle component.

[0061] It can also be understood that in practice, there may be more assembly stations and multiple repair stations.

[0062] Now turning to Figure 3 , and continuing to refer to Figure 1-2 , various method steps for a partially assembled vehicle to autonomously complete its own assembly are described, generally shown as method 300.

[0063] In an application, the functions attributed to the controller circuit 104 can be implemented as one or more sub-modules, and the modules and sub-modules can be distributed among various vehicle systems and components. In various examples, the program 56 and the stored variables and pre-loaded custom operation parameters 58 embody the application processing module of the controller circuit 104.

[0064] For illustrative purposes, the following description of method 300 can be combined with Figure 1-2 reference to the elements mentioned above. In various embodiments, parts of method 300 can be performed by different components of the described partially assembled vehicle 100. It should be understood that method 300 can include any number of additional or alternative operations and tasks, Figure 3 the tasks shown in Figure 3 need not be performed in the sequence shown, and method 300 can be incorporated into a more comprehensive program or method, such as an energy-saving or safety application, which has additional functions not described in detail herein. Additionally,

[0065] At 302, as described above, the method begins with constructing a partially assembled vehicle. The partially assembled vehicle includes: a chassis and wheels rotatably coupled to the chassis; a drive system mounted on the chassis and operatively communicating with the wheels; and, carried on the partially assembled vehicle and operatively communicating with each other: a drive system, a navigation system, a central platform controller, and a position determination system.

[0066] At 304, a safety sensor guidance system is installed on the chassis, the safety sensor guidance system including sensors, a transceiver, and an emergency stop (estop) device; and

[0067] At 306, autonomy begins. This includes responding to receiving a start data packet from an external fleet control source; starting to temporarily take over the central platform controller 108. The start of the temporary takeover can represent a "manufacturing mode", and can include installing or executing a temporary program in the central platform controller 108. The temporary takeover can include applying a temporary power management regime for in-vehicle systems and components via the central platform controller 108, and activating the transceiver 112 to communicate continuously with the external fleet control source. The temporary takeover can include decoding the start data packet (at 308) to identify a plurality of assembly stations that the partially assembled vehicle visits to complete its own assembly. At 308, the method also constructs a sequence for visiting each of the plurality of assembly stations.

[0068] At 310, the method includes commanding the drive system to propel and steer the partially assembled vehicle through the sequence of the plurality of assembly stations. At 310, the command can also be responsive to sensor input from the safety sensor guidance system 110. In some embodiments, the navigation of the partially assembled vehicle through the sequence is monitored by the navigation system 120. In other embodiments, the navigation of the partially assembled vehicle through the sequence is monitored by an auxiliary navigation sensor 406.

[0069] At 312, the method continues to use in-station diagnostics to determine whether an assembly associated with an assembly station passes or fails when the partially assembled vehicle is at each assembly station in the sequence. As used herein, a pass at an assembly station is also considered a successful or completed assembly.

[0070] Each time an assembly station is completed, the partially assembled vehicle 100 advances via a command of the drive system to the next assembly step in the sequence. Thus, step 310 is affected by the result determined at 312. Any sensor 114 is understood to continuously sense the surrounding area as the vehicle advances.

[0071] When the controller circuit 104 and / or the communication structure 402 determine that the partially assembled vehicle has autonomously completed its own assembly, the assembly determination at 314 is completed. In response to 314, the method may terminate the temporary takeover at 316. At 316, the controller circuit 104 may be further programmed to remove the temporary program installed at the start of the temporary takeover (at 306), effectively ending the manufacturing mode and placing the vehicle in customer mode after prompting the external fleet control source that the partially assembled vehicle has autonomously completed its own assembly. At 318, the controller circuit 104 may prompt the external fleet control of the completion of the assembly at 318. As can be understood, after the assembly of the partially assembled vehicle 100 is completed, the components of the safety sensor guidance system 110 may be removed.

[0072] As described above, optional functions supported by the method 300 include: modifying or interrupting the commands of the drive system of the partially assembled vehicle through the sequence in response to receiving a repair data packet from an external fleet control source. Additionally, in various embodiments, an emergency stop (estop) device 118 may be triggered / activated by a person near the partially assembled vehicle 100, and in response to detecting the activation of the emergency stop (estop) device, the controller circuit 104 may prevent the operation of the drive system (specifically, the movement of the wheels 20) until the cause of the activated emergency stop (estop) device has been resolved. Further, the provided partially assembled vehicle 100 may identify its charging requirements and travel to a charging station on its own or in response to a command from the fleet control.

[0073] Accordingly, the provided partially assembled vehicle 100 and the method for the partially assembled vehicle to autonomously complete its own assembly have been described. The provided partially assembled vehicle 100 is autonomous (self-guided and self-powered), which allows the vehicle tires (wheels 20) to be placed on the assembly plant floor rather than on a conveyor belt.

[0074] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that there are numerous variations. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Instead, the foregoing detailed description will provide a convenient roadmap for those skilled in the art to implement one or more exemplary embodiments. Various changes may be made to the functions and arrangements of the elements without departing from the scope of the present disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A partially assembled vehicle that autonomously transports itself through its own assembly process, the partially assembled vehicle comprising: A chassis and wheels, the wheels being rotatably coupled to the chassis; A drive system mounted on the chassis and operatively communicating with the wheels, and further comprising, on the chassis and operatively communicating with each other: a navigation system, a central platform controller, and a position determination system; A safety sensor guidance system is a vehicle mounted to the chassis, the safety sensor guidance system comprising sensors, transceivers, and an emergency stop device; And A controller circuit operatively coupled to the central platform controller and the safety sensor guidance system, the controller circuit being programmed to: In response to receiving a start data packet, initiate a temporary takeover of the central platform controller, the temporary takeover comprising the steps of: Activating the transceiver to continuously communicate with an external fleet control source; Identifying a plurality of assembly stations that the partially assembled vehicle must visit to complete its own assembly; Constructing a sequence for accessing each of the plurality of assembly stations; In response to sensor data from the safety sensor guidance system, commanding the drive system to propel, brake, and steer the partially assembled vehicle through the sequence of the plurality of assembly stations; When the partially assembled vehicle is at each assembly station in the sequence, determining that the assembly associated with the assembly station has been completed when passing a corresponding in-station diagnostic test; Wherein commanding the drive system further is a function of determining that the assembly associated with the current assembly station has been completed for the current assembly station; In response to receiving a repair data packet from the external fleet control source, modifying or interrupting the command of the drive system of the partially assembled vehicle through the sequence; Preventing the drive system from operating in response to detecting the activation of the emergency stop device; After determining that the partially assembled vehicle has completed the sequence, determining that the partially assembled vehicle has autonomously completed its own assembly; and When determining that the partially assembled vehicle has autonomously completed its own assembly, terminating the temporary takeover; and When determining that the partially assembled vehicle has autonomously completed its own assembly, prompting the external fleet control source; The controller circuit is further programmed to perform the following steps: When the partially assembled vehicle is at an assembly station among the plurality of assembly stations, where the partially assembled vehicle visits the assembly station to complete its own assembly, determining that when the in-station diagnostic test fails, the assembly associated with the assembly station is incomplete; Prompting the external fleet control source that the assembly is incomplete; and Wherein commanding the drive system further is a function of responding to a routing instruction for the incomplete assembly.

2. The partially assembled vehicle according to claim 1, wherein, The start data packet identifies the model and configuration information of the partially assembled vehicle, and wherein the controller circuit is further programmed to generate the sequence based on the model and configuration information.

3. The partially assembled vehicle according to claim 1, wherein, The temporary takeover of the central platform controller as described at the beginning includes installing a temporary program into the central platform controller, and wherein the controller circuit is further programmed to: after prompting the external fleet control source that the partially assembled vehicle has autonomously completed its own assembly, remove the temporary program.

4. The partially assembled vehicle according to claim 3, wherein, The temporary program includes instructions for overriding the power distribution in the partially assembled vehicle, and instructions for controlling the functionality of propulsion, braking, and steering.

5. The partially assembled vehicle according to claim 1, wherein, The sequence is one of a plurality of potential sequences for accessing each of the plurality of assembly stations, and wherein the controller circuit is further programmed to: Receive status indicators from each of the plurality of assembly stations; and Construct the sequence based on the received status indicators.

6. The partially assembled vehicle according to claim 1, wherein, The safety sensor guidance system further includes a path projector configured to project a visible light beam forward from the center of the partially assembled vehicle.

7. A method for the full-process autonomous transportation of a partially assembled vehicle to complete its own assembly, the method comprising: Constructing the partially assembled vehicle, the partially assembled vehicle including: a chassis and wheels rotatably coupled to the chassis; a drive system mounted on the chassis and operatively communicating with the wheels; and, carried on the partially assembled vehicle and operatively communicating with each other: a navigation system, a central platform controller, and a position determination system; Installing a safety sensor guidance system onto the chassis, the safety sensor guidance system including sensors, transceivers, and an emergency stop device; and A controller circuit operatively coupled to the central platform controller and the safety sensor guidance system, performing the following steps: Receiving a start data packet from an external fleet control source; In response to receiving the start data packet, initiating a temporary takeover of the central platform controller, the temporary takeover including the following steps: Activating the transceiver to communicate continuously with the external fleet control source; Identifying a plurality of assembly stations that the partially assembled vehicle must access to complete its own assembly; Constructing a sequence for accessing each of the plurality of assembly stations; In response to sensor data from the safety sensor guidance system, commanding the drive system to propel and steer the partially assembled vehicle through the sequence of the plurality of assembly stations; When the partially assembled vehicle is at each assembly station in the sequence, determining that the assembly associated with the assembly station has been completed when passing the corresponding in-station diagnostic test; Wherein commanding the drive system is further a function of determining that the assembly associated with the current assembly station has been completed for the current assembly station; In response to receiving a repair data packet from the external fleet control source, modifying or interrupting the command for the drive system of the partially assembled vehicle to pass through the sequence; Preventing the drive system from operating in response to detecting the activation of the emergency stop device; and Terminating the temporary takeover when determining that the partially assembled vehicle has autonomously completed its own assembly; and When it is determined that the partially assembled vehicle has autonomously completed its own assembly, prompt the external fleet control source; The method further includes performing, by a controller circuit: When the partially assembled vehicle is at each assembly station in the sequence, determining that the assembly associated with the assembly station is incomplete when a diagnostic test within the corresponding station fails; Prompting the external fleet control source of the incomplete status; and Wherein the drive system is commanded to further be a function of a routing instruction in response to the incomplete status.

8. The method according to claim 7, wherein, The starting data packet identifies the model and configuration information of the partially assembled vehicle and further includes generating the sequence based on the model and configuration information, The sequence is one of a plurality of potential sequences for accessing each of the plurality of assembly stations and further includes: Receiving a status indicator from each of the plurality of assembly stations; and Constructing the sequence based on the received status indicators.

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