Radiation-enabled hold features for fixture-free assembly of node-based structures

Abstract

The present invention provides a retention feature for joining at least two structural components in a fixtureless assembly system. A first structure including a groove can be configured to receive at least one adhesive, and a second structure can include a tongue configured to contact the at least one adhesive to join the first and second structures. The first structure can also include at least one window that receives electromagnetic (EM) radiation from a source into the groove. The at least one adhesive is configured to cure at a first rate when exposed to one of time or heat, and the at least one adhesive is configured to cure at a second rate faster than the first rate when exposed to the EM radiation.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Patent Application No. 16 / 940,754, filed on July 28, 2020, entitled “RADIATION-ENABLED RETENTION FEATURES FOR FIXTURELESS ASSEMBLY OF NODE-BASED STRUCTURES.” The contents of said patent application are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure relates to a retention feature for assembling structures, and more particularly, to a radiation-enabled retention feature for fixtureless assembly of structures. Background Art

[0004] Vehicles such as cars, trucks, or airplanes are made from a large number of individual structural components that are joined together to form the body, frame, interior and exterior surfaces, etc. These structural components provide the car, truck, and airplane with form and the ability to respond appropriately to the many different types of forces generated or caused by various actions such as acceleration and braking. These structural components also provide support. Structural components of various sizes and geometries can be integrated into the vehicle, for example, to provide interfaces between panels, extrusions, and / or other structures. Therefore, structural components are an integral part of the vehicle.

[0005] Modern automotive factories rely heavily on the robotic assembly of structural components. However, robotic assembly of automotive components often relies on the use of fixtures to securely hold the structural components during the assembly process. For example, in an automotive factory, each part of a car that undergoes robotic assembly may require a unique fixture dedicated to that part. Given the large number of individual parts in a car that are robotically assembled, an equally large number of fixtures may be required, leading to increased costs. Furthermore, fixtures are often only usable for the specific part for which they were designed. Summary of the Invention

[0006] Several aspects of an assembly system including apparatus for joining at least two structural components without the use of fixtures during the robotic assembly of at least a portion of a vehicle are described more fully below.

[0007] In various aspects, a device may include a first structure including a groove and at least one window, the groove configured to receive at least one adhesive to couple the first structure to a second structure, the at least one window receiving electromagnetic (EM) radiation into the groove. The at least one adhesive cures at a first rate when exposed to one of time or heat, and cures at a second rate faster than the first rate when exposed to the EM radiation.

[0008] In various aspects, an assembly system may include a first material handling robot configured to hold a first structure, wherein the first structure includes a recess for receiving at least one adhesive. The assembly system may also include an EM radiation source configured to emit EM radiation into the recess. The at least one adhesive cures at a first rate when exposed to one of time or heat, and cures at a second rate faster than the first rate when exposed to the EM radiation.

[0009] In various aspects, an apparatus may include a first structure including a groove that receives at least one adhesive, and a second structure coupled to the first structure and including a tongue that contacts the at least one adhesive. The at least one adhesive is configured to cure at a first rate when exposed to one of time or heat, and the at least one adhesive is configured to cure at a second rate that is faster than the first rate when exposed to EM radiation.

[0010] Other aspects will be readily apparent to those skilled in the art from the following detailed description, wherein only a few embodiments are shown and described by way of illustration. As will be appreciated by those skilled in the art, the concepts herein are capable of other and different embodiments, and all of the details are capable of modification in various other respects without departing from the present disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Various aspects will now be presented, by way of example and not by way of limitation, in the detailed description of the accompanying drawings in which:

[0012] Figure 1 A perspective view of an exemplary assembly system including a plurality of robots configured to assemble at least a portion of a vehicle is shown.

[0013] Figures 2A-2B An example of a first structure is shown that includes a recess for receiving a fast-curing adhesive.

[0014] Figures 3A-3BAn example of a second structure is shown that includes a tongue for contacting a fast-curing adhesive.

[0015] Figures 4A-4B Shown Figures 2A-2B The first structure and Figures 3A-3B An example of a second structural connection.

[0016] Figure 5 Shown for Figures 3A-3B Various examples of tongue types of the second structure.

[0017] Figure 6 Another example of a first structure is shown that includes a recess with compartments for separately containing a structural adhesive and a fast-setting adhesive.

[0018] Figure 7 Another example of a first structure is shown that includes recesses that accommodate a single structural adhesive and a fast-setting adhesive.

[0019] Figures 8A-8H A perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembly of at least a portion of a vehicle is shown.

[0020] Figure 9 is a block diagram of an example controller processing system configured to execute one or more sets of instructions to direct at least one robot to perform various operations associated with assembly of at least a portion of a vehicle. DETAILED DESCRIPTION

[0021] The detailed description set forth below in conjunction with the accompanying drawings is intended to provide a description of various exemplary embodiments of the concepts disclosed herein and is not intended to represent the only embodiment in which the present disclosure may be practiced. The term "exemplary" as used in this disclosure means "serving as an example, instance, or illustration" and should not necessarily be interpreted as being more preferred or more advantageous relative to other embodiments presented in this disclosure. In order to provide a thorough and complete disclosure that fully conveys the scope of the concepts to those skilled in the art, the detailed description includes specific details. However, the present disclosure 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.

[0022] In order to provide a more economical method for automatically assembling a transport structure (e.g., a vehicle chassis) without requiring a large number of fixtures that depend on the chassis design, fixture-free, non-specifically designed components for structural components can be used. For example, a robot can be configured to directly hold a structure, for example using an end effector of a robotic arm, and position the structure during the assembly process and couple the structure to another structure held by another robot. The structure can be, for example, a node, a tube, an extrusion, a panel, a workpiece, a part, a component, an assembly or a subassembly (e.g., comprising at least two previously coupled structures), etc. For example, the structure or part can be at least a portion or at least one section associated with a vehicle, such as a vehicle chassis, a panel, a base workpiece, a body, a frame, and / or another vehicle component. A node is a structure that can include one or more interfaces for connecting to other structures (e.g., a tube, a panel, etc.). The structure can be produced using additive manufacturing (AM) (e.g., 3-D printing).

[0023] Figure 1 A perspective view of an example of a fixtureless assembly system 100 is shown. The fixtureless assembly system 100 can be used in various operations associated with fixtureless assembly of a vehicle, such as robotic assembly of a node-based vehicle. The fixtureless assembly system 100 can include one or more elements associated with at least a portion of a component of a vehicle that is free of any fixtures. For example, one or more elements of the fixtureless assembly system 100 can be configured for one or more operations in which a first structure is coupled to one or more other structures without the use of any fixtures during robotic assembly of a node-based vehicle.

[0024] The assembly unit 105 can be configured at the location of the fixtureless assembly system 100. The assembly unit 105 can be a vertical assembly unit. Within the assembly unit 105, the fixtureless assembly system 100 can include a group of robots 107, 109, 111, 113, 115, 117. The robot 107 can be referred to as a keystone robot. The fixtureless assembly system 100 can include a part table 121 that can hold parts and structures for robot access. For example, a first structure 123 and a second structure 125 can be positioned on one of the part tables 121 to be picked up by a robot and assembled together. In various embodiments, one or more of the structures can be additively manufactured structures, such as complex nodes.

[0025] The fixtureless assembly system 100 may also include a computing system 129 to issue commands to various controllers of the robot of the assembly cell 105. In this example, the computing system 129 is in communication with the robot via wireless communication. The fixtureless assembly system 100 may also include a metrology system 131 that can accurately measure the position of the robot's robotic arm and / or the position of the structure held by the robot.

[0026] Unlike traditional robotic assembly plants, in the fixtureless assembly system 100, structures can be assembled without fixtures. For example, the structures do not need to be connected within any fixtures (such as the fixtures described above). Instead, at least one of the robots in the assembly unit 105 can provide the functionality expected of a fixture. For example, the robots can be configured (e.g., using the end effector of a robotic arm) to directly contact the structures to be assembled within the assembly unit 105 so that those structures can be engaged and held without any fixtures. In addition, at least one of the robots can provide the functionality expected of a positioner and / or fixture table. For example, the key robot 107 can replace the positioner and / or fixture table in the fixtureless assembly system 100.

[0027] The key robot 107 may include a base and a robotic arm. The robotic arm may be configured for movement, which may be guided by computer-executable instructions loaded into a processor communicatively coupled to the key robot 107. The key robot 107 may contact a surface of the assembly cell 105 (e.g., a floor of the assembly cell) via the base.

[0028] The key robot 107 may include and / or be connected to an end effector configured to engage and retain a first structure, such as a portion of a vehicle. The end effector may be a component configured to interface with at least one structure. Examples of end effectors may include a clamp, a gripper, a pin, or other similar component that facilitates fixtureless engagement and retention of the structure by the robot. In some embodiments, the first structure may be a portion of a vehicle chassis, body, frame, panel, base workpiece, etc. For example, the first structure may include a floor panel.

[0029] In some embodiments, the key robot 107 can maintain connection to a first structure via an end effector while a set of other structures are connected (directly or indirectly) to the first structure. The key robot 107 can be configured to engage and hold the first structure without any fixtures, e.g., without any of the fixtures described above being present in the fixtureless assembly system 100. In some embodiments, the structures held by at least one of the robots (e.g., the first structure) can be additively manufactured or co-printed with one or more features that facilitate engagement and retention of those structures by at least one of the robots without the use of any fixtures.

[0030] While holding the first structure, the key robot 107 can position (e.g., move) the first structure; that is, the position of the first structure can be controlled by the key robot 107 when held by the key robot. The key robot 107 can hold the first structure by holding or grasping the first structure, such as using the end effector of the key robot's robotic arm. For example, the key robot 107 can hold the first structure by causing a gripper finger, clamp, etc. to contact one or more surfaces of the first structure and apply sufficient pressure thereto so that the key robot controls the position of the first structure. That is, when held by the key robot 107, the first structure can be prevented from moving freely in space, and the movement of the first structure can be constrained by the key robot. As described above, the first structure may include one or more features that assist the key robot 107 in fixture-free engagement and retention of the first structure.

[0031] When other structures (including subassemblies, substructures of structures, etc.) are connected to the first structure, the key robot 107 can maintain engagement with the first structure through the end effector. The first structure and one or more structures connected thereto can be referred to as the structure itself, but can also be referred to as an assembly or subassembly. Once the key robot has engaged the first structure, the key robot 107 can maintain engagement with the assembly.

[0032] In some embodiments, robots 109 and 111 of assembly cell 105 can be similar to key robot 107 and, therefore, can include respective end effectors configured to engage a structure that can be connected to a first structure when held by the key robot. In some embodiments, robots 109, 111 can be referred to as assembly robots and / or material handling robots.

[0033] In some embodiments, the robot 113 of the assembly unit 105 can be used to affect a structural connection between a first structure and a second structure. For example, the robot 113 can be referred to as a structural adhesive robot. The structural adhesive robot 113 can be similar to the key robot 107, except that the structural adhesive robot can include a tool located at the distal end of the robotic arm that is configured to apply a structural adhesive to at least one surface of a structure held without a clamp by the key robot and at least one surface of a structure held without a clamp by the assembly robots 109, 111 before or after the structure is positioned at a joining proximity relative to the other structure to be joined to the other structure. The joining proximity can be a position that allows the first structure to be joined to the second structure. For example, in various embodiments, the first structure and the second structure can be combined by applying an adhesive while the structures are located within the joining proximity and then curing the adhesive.

[0034] In various embodiments, a fast-curing adhesive may be additionally applied to quickly join and hold the structures so that the structural adhesive can cure without requiring two robots to hold the structures. In this regard, the robot 115 of the fixtureless assembly system 100 may be used to apply the fast-curing adhesive and quickly cure the adhesive. In this example embodiment, a fast-curing UV adhesive may be used, and the robot 115 may be referred to as a UV robot. The UV robot 115 may be similar to the key robot 107, except that the UV robot may include a tool located at the distal end of the robotic arm that is configured to apply the fast-curing UV adhesive and cure the adhesive, for example, when the first structure is positioned within the proximal side of the joint relative to the second structure. That is, when the first structure and / or the second structure are located within the proximal side of the joint obtained by the direction of at least one of the robotic arms of the key robot 107 and / or the assembly robots 109, 111, the UV robot 115 may cure the adhesive after the adhesive is applied to the first structure and / or the second structure.

[0035] In various embodiments, robots can be used for a variety of different roles. For example, robot 117 can perform the role of an assembly robot such as assembly robots 109, 111 and the role of a UV robot such as UV robot 115. In this regard, robot 117 can be referred to as an "assembly / UV robot". When the distal end of the assembly / UV robot's robotic arm includes an end effector (e.g., connected by a tool flange), the assembly / UV robot 117 can provide functions similar to each of the assembly robots 109, 111. However, when the distal end of the assembly / UV robot's robotic arm includes a tool configured to apply UV adhesive and emit UV light to cure the UV adhesive, the assembly / UV robot 117 can provide functions similar to those of the UV robot 115.

[0036] The fast-curing adhesive applied by UV robot 115 and assembly / UV robot 117 can provide a partial adhesive bond in that the adhesive can maintain the relative position of the first and second structures within the joint proximal side until the structural adhesive can cure to permanently join the first and second structures.

[0037] When assembling at least a portion of the vehicle in the assembly cell 105, the second structure can be directly coupled to the first structure by guiding the various fixtureless robots 107, 109, 111, 113, 115, 117. Additional structures can be indirectly coupled to the first structure. For example, the first structure can be directly coupled to the second structure through the movement of the key robot 107, the structural adhesive robot 113, at least one assembly robot 109, 111 and / or the UV robot 115. Thereafter, when the additional structure is directly coupled to the second structure, the first structure coupled to the second structure can be indirectly coupled to the additional structure. Therefore, the first structure, which can continue to be held by the key robot 107, can evolve throughout the assembly process as additional structures are directly or indirectly coupled to it.

[0038] In some embodiments, the assembly robots 109, 111 may, before joining the two or more structures to the first structure held by the key robot 107 without clamps, for example, by bonding the two or more structures together with a partially fast-curing adhesive. The two or more structures that are joined to each other before being joined to the structural assembly may also be a structure and may further be referred to as a subassembly. Thus, when a structure forms part of a structural subassembly that is connected to the first structure by movement of the key robot 107, the structural adhesive robot 113, at least one assembly robot 109, 111, and the UV robot 115, the structure of the structural subassembly may be indirectly connected to the first structure when the structural subassembly is joined to the structural assembly that includes the first structure.

[0039] In some embodiments, a structural adhesive can be applied before the first and second structures are placed within the proximal range of the connection, for example, the structural adhesive is deposited in a groove of one of the structures. For example, the structural adhesive robot 113 may include a dispenser for the structural adhesive and may apply the structural adhesive before the structures are placed within the proximal range of the connection. In some embodiments, the structural adhesive can be applied after the structural assembly is fully constructed (i.e., once each structure of a portion of the vehicle is coupled to the first structure). For example, the structural adhesive can be applied to one or more joints or other connections between the first and second structures. In some embodiments, the structural adhesive can be applied separately from the fixtureless assembly system 100.

[0040] After assembly is complete, i.e., all structures are assembled, held in place by the partial adhesive, and the structural adhesive has been applied, the structural adhesive can be cured. While the structural adhesive is curing, the portion of the vehicle can be complete and thus suitable for use in the vehicle. For example, the completed structural assembly can meet any applicable industry standards and / or safety standards defined for consumer and / or commercial vehicles.

[0041] According to various embodiments, one or more of the robots 107, 109, 111, 113, 115, 117 can be secured to a surface of the assembly cell 105 via a corresponding base of each robot. For example, one or more of the robots can have a base that is bolted to the floor of the assembly cell. In various other embodiments, one or more of the robots can include or be connected to a component configured to move the robot within the assembly cell 105. For example, the carrier 119 in the assembly cell 105 can be connected to the component / UV robot 117.

[0042] Each of the robots 107, 109, 111, 113, 115, and 117 may include features common to all or some of the robots. For example, all of the robots may include a base, each of which has a surface (e.g., a bottom surface) that contacts the assembly unit 105 (e.g., placed on or fixed to the bottom plate of the assembly unit). Each base may have another surface (e.g., a top surface and / or a surface provided on the base opposite to the surface that contacts the assembly unit 105), and the base may be connected to the proximal end of the corresponding robotic arm of a corresponding one of the robots at the corresponding other surface.

[0043] In some embodiments, the base can be coupled to the proximal end of the robotic arm via at least one rotational mechanism and / or translational mechanism. The at least one rotational mechanism and / or translational mechanism can provide at least one degree of freedom in the movement of an end effector or other tool of the robotic arm. Accordingly, the at least one rotational mechanism and / or translational mechanism can provide at least one degree of freedom in the movement of a structure engaged and held by the end effector or other tool of the robotic arm.

[0044] Each of the robotic arms of robots 107, 109, 111, 113, 115, 117 may include a distal end that is disposed opposite the proximal end of the robotic arm. Each of the robotic arms of each robot may include an end effector and / or a tool, such as an adhesive application tool, a curing tool, etc. The end effector or tool may be located at the distal end of the robotic arm. In some embodiments, the distal end of the robotic arm may be connected to the end effector or tool (or tool flange) by at least one rotational mechanism and / or translational mechanism that may provide at least one degree of freedom in the movement of the tool and / or the movement of a structure engaged and held by the tool of the robotic arm.

[0045] In some embodiments, the distal end of the robotic arm may include a tool flange and a tool included at the tool flange; for example, the tool may be connected to the distal end of the robotic arm by means of the tool flange. The tool flange can be configured to include multiple tools. In this way, for example, when the distal end of the robotic arm of the assembly / UV robot 117 includes an end effector (e.g., connected by means of a tool flange), the assembly / UV robot 117 can provide functions similar to each of the assembly robots 109 and 111. In addition, when the distal end of the robotic arm of the assembly / UV robot 117 includes a tool configured to apply UV adhesive and emit UV light to cure the UV adhesive, the assembly / UV robot 117 can provide functions similar to those of the UV robot 115.

[0046] According to some embodiments, the tool flange and / or the tool can provide one or more additional degrees of freedom for rotation and / or translation of the structure engaged and held by the tool. Such additional degrees of freedom can supplement the one or more degrees of freedom provided by one or more mechanisms connecting the base to the proximal end of the robotic arm and / or connecting the distal end of the robotic arm to the tool (or tool flange). Illustratively, the robotic arm of at least one of robots 107, 109, 111, 113, 115, 117 can include at least one joint configured for rotation and / or translation at the distal end and / or proximal end, such as an articulated joint, a ball joint, and / or other similar joints.

[0047] One or more of the corresponding connectors of the robots 107, 109, 111, 113, 115, 117 (e.g., one or more rotational and / or translational mechanisms connecting various components of one of the robots), corresponding tool flanges, and / or corresponding tools can provide at least a portion (and possibly all) of the six degrees of freedom (6DoF) for the structure engaged and held by the robot. The 6DoF can include forward / backward (e.g., wave), up / down (e.g., heave), left / right (e.g., yaw) for translation in space, and can further include yaw, pitch, and roll for rotation in space. Access to various portions of a structure can be achieved through one or more of the 6DoF, as opposed to retaining a structure using a clamp, which may not provide 6DoF for movement of the structure and may also hinder access to important portions of the structure to which it is attached.

[0048] Each of the robots 107, 109, 111, 113, 115, 117 can communicate with a controller (e.g. Figure 1 Each of the controllers 137, 139, 141, 143, 145, 147 may include, for example, a memory and a processor (e.g., as described below with respect to a processor) that is communicatively connected to the memory. Figure 9 According to some other embodiments, one or more of the controllers 137, 139, 141, 143, 145, 147 may be implemented as a single controller that is communicatively connected to one or more of the robots controlled by the single controller.

[0049] Computer-readable instructions for performing fixtureless assembly can be stored in the memory of the controllers 137, 139, 141, 143, 145, 147, and the processor of the controller can execute the instructions to cause the robots 107, 109, 111, 113, 115, 117 to perform various fixtureless operations, such as the operations described above.

[0050] The controllers 137, 139, 141, 143, 145, 147 can be communicatively connected to one or more components of the associated robot 107, 109, 111, 113, 115, or 117, for example, via a wired (e.g., bus or other interconnect) connection and / or a wireless (e.g., wireless local area network, wireless intranet) connection. For example, each of the controllers can issue commands, requests, etc. to one or more components of the associated robot in order to perform various gripper-free operations.

[0051] According to some embodiments, controllers 137, 139, 141, 143, 145, 147 can issue commands, etc., to the robotic arm of the associated robot 107, 109, 111, 113, 115, or 117, and can, for example, guide the robotic arm based on a set of absolute coordinates relative to the global unit reference frame of assembly unit 105. In various embodiments, controllers 137, 139, 141, 143, 145, 147 can issue commands, etc., to a tool connected to the distal end of the robotic arm. For example, the controller can control the operation of the tool, including depositing a controlled amount of adhesive on the surface of a first structure or a second structure via an adhesive applicator, exposing the adhesive deposited between the structures to UV light for a controlled duration via a curing tool, etc. In various embodiments, controllers 137, 139, 141, 143, 145, 147 can issue commands, etc., to an end effector at the distal end of the robotic arm. For example, the controller can control the operation of the end effector, including engaging, holding, and / or manipulating a structure.

[0052] According to various other aspects, a computing system similarly having a processor and memory (such as computing system 129) can be communicatively connected to one or more of the controllers 137, 139, 141, 143, 145, 147. In various embodiments, the computing system can be communicatively connected to the controllers via a wired connection and / or a wireless connection (such as a local area network, an intranet, a wide area network, etc.). In some embodiments, the computing system can be implemented in one or more of the controllers 137, 139, 141, 143, 145, 147. In some other embodiments, the computing system can be located outside the assembly unit 105. Figure 9 An example of such a computing system is described.

[0053] The processor of the computing system can execute instructions loaded from the memory, and the execution of the instructions can cause the computing system to send commands, etc. to the controllers 137, 139, 141, 143, 145, 147, such as by sending a message including the commands, etc. to one of the controllers using a network connection or other communication link.

[0054] According to some embodiments, one or more of the commands may indicate a set of coordinates and may indicate an action to be performed by one of the robots 107, 109, 111, 113, 115, 117 associated with one of the controllers receiving the command. Examples of actions that may be indicated by the commands include directing movement of a robotic arm, manipulating a tool, engaging a structure via an end effector, rotating and / or translating a structure, etc. For example, a command issued by the computing system may cause the controller 139 of the assembly robot 109 to direct the robotic arm of the assembly robot 109 so that the distal end of the robotic arm may be positioned based on the set of coordinates indicated by the command.

[0055] The instructions loaded from the memory and executed by the processor of the computing system can be based on computer-aided design (CAD) data, which instructions cause the controller to control the actions of the robot. For example, a CAD model of the assembly unit 105 (e.g., including a CAD model of the physical robot) can be constructed and used to generate the commands issued by the computing system.

[0056] Thus, in one example of a fixtureless assembly process, multiple robots (e.g., robots 107, 109, 111, 113, 115, and / or 117) are controlled (e.g., by computing system 129 and / or one or more controllers 137, 139, 141, 143, 145, 147) to join two structures together within an assembly cell (e.g., a vertical assembly cell such as assembly cell 105). The assembly operation can be repeated so that multiple structures can be joined for fixtureless assembly of at least a portion of a vehicle (e.g., a vehicle chassis, body, panel, etc.). A first material handling robot (e.g., robot 109) can hold (e.g., using an end effector) a first structure (e.g., first structure 123) to be joined to a second structure (e.g., second structure 125) similarly held by a second material handling robot (e.g., robot 111). A structural adhesive dispensing robot (e.g., robot 113) can apply structural adhesive to a surface of the first structure held by the first robot. The first material handling robot can then position the first structure relative to the second structure held by the second material handling robot at the near side of the joint. A metrology system (e.g., metrology system 131) can implement a move-measure-correct (MMC) procedure to accurately measure, correct, and move the robot's robotic arm and / or the structure held by the robot into an optimal position at the near side of the joint (e.g., using laser scanning and / or tracking).

[0057] The positioned structures (e.g., structures 123 and 125) can then be joined together using a structural adhesive and cured (e.g., over time or using heat). However, because the curing rate of the structural adhesive can be relatively slow, when the first and second structures are within the proximal range of the joint, a fast-cure adhesive robot (e.g., robot 115 or robot 117) can additionally apply the fast-cure adhesive to the first and / or second structures. The fast-cure adhesive robot can then switch to an end effector that emits electromagnetic (EM) radiation (e.g., ultraviolet (UV) radiation) onto the fast-cure adhesive. For example, the fast-cure adhesive robot can apply a strip of UV adhesive to the surface of the first and / or second structures so that the UV adhesive contacts the two structures. The robot can then emit UV radiation onto the strip of UV adhesive. Upon exposure to the EM radiation, the fast-cure adhesive cures at a faster rate than the curing rate of the structural adhesive, thereby allowing the first and second structures to remain in their relative positions without a fixture, allowing the robot to quickly perform other tasks (e.g., holding and joining other parts) without having to wait for the structural adhesive to cure. Once the structural adhesive cures, the first structure and the second structure are bonded with structural integrity.

[0058] However, because the first and second structures in the proximal portion of the joint can be oriented in a variety of positions, the UV adhesive strips contacting the surfaces may occasionally move (e.g., fall off). For example, one structure may be positioned upside down relative to the other, and the UV adhesive may therefore fall off due to gravity. As a result, when the UV adhesive cures, the first and second structures may be unintentionally held in positions that do not provide an acceptable tolerance, thereby affecting the structural integrity of the assembly.

[0059] The difficulty in applying UV adhesive near the joint may also lead to improper retention of structures. For example, a material handling robot that holds the first and second structures near the joint may be tightly packed in an assembly cell. Therefore, a fast-curing adhesive robot may have difficulty maneuvering around the material handling robot and applying UV adhesive to the structures near the joint within this tightly packed area. In addition, since the metering system can also use laser tracking to perform MMC on these structures in this tightly packed area, the fast-curing adhesive robot may potentially hinder the laser and MMC process when attempting to apply UV adhesive. Therefore, the entire assembly may be affected. For example, when forming an assembly by stacking different parts, the misalignment of one structure may affect the alignment of other parts supported by the structure. In addition, since structures and subassemblies frequently move during the assembly process, improper retention may cause the structure or subassembly to deflect or fall from the assembly.

[0060] To reduce the likelihood of improper retention of structures during the fixtureless assembly process, the present disclosure provides retention features in the first and second structures (eg, first and second structures 123 and 125) that allow for application of a fast-curing adhesive prior to placing the structures proximal to the joint. Figure 2A and 2B An example of a first structure 200 is shown that includes a retaining feature in the form of a recess (eg, depression, etc.), and Figure 3A and 3B An example of a second structure 300 is shown that includes a retaining feature in the form of a tongue (eg, a protrusion, etc.). Figure 4A and 4B An example of a subassembly 400 is shown that includes a first structure 402 (eg, first structure 200 ) coupled to a second structure 406 (eg, second structure 300 ) using the aforementioned retention features.

[0061] Referring to the aforementioned figures, the first structure 123, 200, 402 of the subassembly 300 includes a groove 202 into which an adhesive dispensing robot (e.g., robot 113, 115, or 117) can inject a fast-curing adhesive 404. The first structure can also include a window 204 (e.g., a translucent or transparent screen) opposite the groove into which the fast-curing adhesive robot can emit EM radiation to cure the fast-curing adhesive contained within the groove. The second structure 125, 300, 406 of the subassembly 400 can include a tongue 302 that a material handling robot (e.g., robot 109 or 111) can place into the fast-curing adhesive within the groove of the first structure. The tongue can include a plurality of segments 304 (e.g., spaced apart from each other) that are spaced apart from each other. Figure 5 comb shape 506) or multiple openings (e.g. Figure 5 502), these segments or openings contact the fast-curing adhesive when the tongue is inserted into the groove. Although the "first" structure is referred to herein as having a groove and the "second" structure is referred to herein as having a tongue, the present disclosure is not limited thereto. For example, the second structure 125, 300, 346 may include a groove to accommodate the fast-curing adhesive, and the first structure 123, 200, 402 may include a tongue to be inserted into the fast-curing adhesive.

[0062] The tongue 302 may be selected from various types. Figure 5Examples of different tongue types 500 are shown. For example, the tongue can include a waffle shape 502, a fork shape 504, a comb shape 506, a ring shape 508, or a snake shape 510. The tongue can alternatively take other shapes. The shape of the tongue can be selected to maximize the strength of the adhesive bond between the first structure and the second structure and / or to optimize printability (e.g., in additive manufacturing). For example, when the tongue is adhered in a groove, a tongue with a comb shape 506 may require a maximum pull force of approximately 100N greater than that of tongues with other aforementioned tongue types (e.g., due to the additional surface area contacting the adhesive between the plurality of segments 304). Therefore, a comb-shaped tongue can be selected for tongue 302 to maximize strength. Alternatively, a waffle-shaped tongue 502 can be selected, which has similar strength (but slightly less), because a waffle shape can be easier to print than the other aforementioned tongue types (e.g., due to the multiple openings in the waffle shape). Therefore, a waffle-shaped tongue may be selected instead for tongue 302 to optimize printability. Other tongue types may be selected to balance adhesive strength and printability.

[0063] In one example, the structural adhesive can be separate from the fast-cure adhesive. That is, the structural adhesive can be a first adhesive that cures at a first cure rate when exposed to time or heat, and the fast-cure adhesive can be a second adhesive that cures at a second cure rate that is faster than the first cure rate when exposed to EM radiation (e.g., UV radiation). Figure 6 An example of a first structure 600 (e.g., first structure 123, 200, 402) is shown that includes a groove 602 (e.g., groove 202) that holds a structural adhesive 604 and a fast-curing adhesive 606 in separate compartments. For example, the groove may include one or more first compartments 608 for holding the structural adhesive and one or more second compartments 610 for holding the fast-curing adhesive. One or more windows 612 (e.g., window 204) may be positioned opposite the second compartments to allow the fast-curing adhesive to be exposed to EM radiation (e.g., UV radiation) for curing. The compartments 608, 610 also serve to prevent the structural adhesive and the fast-curing adhesive from mixing. Thus, the fast-curing adhesive exposed to EM radiation through the one or more windows may cure at a faster second cure rate, while the structural adhesive cures at a slower first cure rate.

[0064] In another example, the structural adhesive and the fast-curing adhesive can be a single adhesive. That is, the structural adhesive and the fast-curing adhesive can be combined into an adhesive that cures at a first cure rate when exposed to time or heat and cures at a second cure rate that is faster than the first cure rate when exposed to EM radiation (e.g., UV radiation). Figure 7 An example of a first structure 700 (e.g., first structure 123, 200, 402) including a recess 702 (e.g., recess 202) containing a single structural and fast-curing adhesive 704 is shown. Figure 6 Unlike the example shown, in the illustrated example, the structural and fast-curing adhesive can be contained in a single compartment 706 within the recess. One or more windows 708 (e.g., window 204) can be provided at one or more locations to allow one or more portions of the structural and fast-curing adhesive to be exposed to EM radiation (e.g., UV radiation). Thus, the one or more portions of the structural and fast-curing adhesive exposed to the EM radiation can be cured at a faster second cure rate, while the remaining portions of the adhesive not exposed to the EM radiation are cured at a slower first cure rate.

[0065] Now refer to Figures 8A to 8H Example operations of a fixtureless assembly system 800 (e.g., fixtureless assembly system 100) in connection with a first structure 123, 200, 402, 600, 700 and a second structure 125, 300, 406 are described. As described herein, the example operations can be caused by at least one of the controllers 137, 139, 141, 143, 145, 147 communicatively coupled to the robots 107, 109, 111, 113, 115, 117. In some embodiments, the computing system 129 can issue commands to the controllers 137, 139, 141, 143, 145, 147 to cause the example operations. The computing system 129 and / or the controllers 137, 139, 141, 143, 145, 147 can cause the example operations based on CAD data that can model a physical robot performing the example operations and / or position data that can be provided by the metrology system 131.

[0066] For the example operations of the fixtureless assembly system 800, the robots 107, 109, 111, 113, 115, 117 can be positioned relatively close to each other, for example, at a distance suitable for the following example operations. In some embodiments, prior to the following example operations, one or more robots 107, 109, 111, 113, 115, 117 can be positioned in the fixtureless assembly system 800 at a position suitable for one or more example operations. In such a position, the corresponding bases of those one or more robots can be static throughout the example operations of the fixtureless assembly system 800. However, the movement of the robotic arms of the robots 107, 109, 111, 113, 115, 117 can be coordinated and controlled at various stages of the fixtureless assembly system 800, such as by rotating around the corresponding bases, rotating at hinges, etc.

[0067] In some other embodiments, different robots 107, 109, 111, 113, 115, 117 can be dynamically (re)positioned at different distances from each other at different stages of fixture-free assembly. The carrier 119 can be configured to move one or more robots 107, 109, 111, 113, 115, 117 to their corresponding positions, for example, according to the execution of one or more processors of one or more sets of instructions associated with fixture-free assembly. Whether static or dynamic, the respective positions of each of the robots 107, 109, 111, 113, 115, 117 can be based on one or more sets of coordinates (e.g., one or more sets of absolute coordinates) associated with the fixture-free assembly system 800.

[0068] First reference Figure 8A, an assembly robot 802 (e.g., robot 109, 111) can engage a first structure 804 (e.g., first structure 123, 200, 402, 600, 700). The first structure can include one or more features that can couple the first structure to one or more other structures. Illustratively, the first structure can include a groove 806 (e.g., groove 202, 602, 702) on a first surface and can include a tongue (e.g., tongue 302) on a second surface. Groove 806 can include one or more first compartments 807 (e.g., first compartment 608), one or more second compartments 809 (e.g., second compartment 610), and one or more windows 811 (e.g., windows 204, 612) disposed opposite the second compartments. Alternatively, groove 806 can include a single compartment (e.g., compartment 706), and window 811 (e.g., window 708) can be disposed opposite the single compartment. The first and second surfaces of the first structure 804 may be generally opposing surfaces (eg, the first surface may be located on the left or top side of the first structure, while the second surface may be located on the right or bottom side of the first structure, or vice versa).

[0069] The assembly robot 802 can be positioned relatively close to the part table 808 (e.g., the part table 121). In such a position, the robotic arm of the assembly robot 802 can be within a proximal range of at least a portion of the part located on the part table 808. Figure 8A In the example embodiment, the assembly robot 802 can be located to one side of the part table 808, and at this position of the assembly robot 802, the tongue of the first structure 804 can be relatively closer to the assembly robot 802 than the groove 806 of the first structure 804.

[0070] The assembly robot 802 can be connected to an end effector 810. Illustratively, the distal end of the robotic arm of the assembly robot 802 can be connected to the end effector 810, which can be built into the distal end of the robotic arm (where the proximal end of the robotic arm is connected to the assembly robot 802) or can be attached to the robotic arm (and can be fixed or removable). The end effector 810 of the assembly robot 802 can be configured to engage (e.g., pick up) and hold one or more structures. For example, the end effector 810 of the assembly robot 802 can be configured to engage with different structures, such as via one or more features of the different structures. Some examples of such end effectors can include forceps or grippers.

[0071] The assembly robot 802 can engage the first structure 804, for example, generally on the side of the groove 806 of the first structure 804. Specifically, the robotic arm of the assembly robot 802 can move to a position where the end effector 810 of the assembly robot 802 can engage the first structure 804. At this position, the end effector 810 of the assembly robot 802 engages the first structure 804, for example, on the same side and / or surface as the tongue of the first structure 804. Once engaged, the assembly robot 802 can hold the first structure 804, for example, with the aid of the end effector 810. While the first structure 804 is held by the assembly robot 802, the assembly robot 802 can move the first structure 804 to one or more positions at which one or more example operations of fixtureless assembly can be performed, as further described below.

[0072] Next reference Figure 8B , the assembly robot 802 can be turned to face the structural adhesive robot 812. The distal end of the robotic arm of the assembly robot 802 can be positioned toward the structural adhesive robot 812, and, similarly, the distal end of the robotic arm of the structural adhesive robot 812 can be positioned toward the assembly robot 802.

[0073] exist Figure 8B In the example position shown, assembly robot 802 can move first structure 804 to a position where first structure 804 is approximately between assembly robot 802 and structural adhesive robot 812. Additionally, assembly robot 802 can orient first structure 804 such that recess 806 of first structure 804 faces generally upward, such as by moving a robotic arm of assembly robot 802 and / or an end effector 810 of assembly robot 802 to orient first structure 804 generally upward.

[0074] The structural adhesive robot 812 can be connected to a structural adhesive applicator 814 or other similar tool. Illustratively, the distal end of the robotic arm of the structural adhesive robot 812 can be connected to the structural adhesive applicator 814, which can be built into the distal end of the robotic arm (where the proximal end of the robotic arm is connected to the structural adhesive robot 812) or can be attached to the robotic arm (and can be fixed or removable). The structural adhesive applicator 814 of the structural adhesive robot 812 can be configured to deposit adhesive onto a structural surface.

[0075] When the first structure 804 is appropriately positioned (e.g., positioned between the two robots 802, 812), the structural adhesive robot 812 can apply adhesive to the first structure 804. Specifically, the structural adhesive robot 812 can deposit structural adhesive 816 into the groove 806 of the first structure 804. To do so, the structural adhesive robot 812 can move its robotic arm to a position such that the structural adhesive applicator 814 is positioned above the groove 806 of the first structure 804 and close enough to deposit a controlled amount of adhesive within a defined area while avoiding deposition of adhesive on unintended surfaces or portions of unintended surfaces. For example, where the groove 806 includes the first compartment 807, the defined area in which the structural adhesive 816 is deposited can include the first compartment 807 but not the second compartment 809. In such a position, the adhesive application tip of the structural adhesive applicator 814 can be positioned substantially directly above the groove 806 and can point downwardly into the groove 806 (e.g., into the first compartment 807).

[0076] When properly positioned, the structural adhesive robot 812 can cause the structural adhesive applicator 814 to deposit a controlled amount of adhesive into the recess 806. The controlled amount of adhesive can at least partially fill the recess 806. In some embodiments, the controlled amount of adhesive can completely or nearly completely fill the first compartment 807 of the recess 806. However, the amount of adhesive can be controlled so that the adhesive does not overflow outside the recess 806 and does not overflow onto the first surface of the first structure 804 that defines the recess 806. For example, the amount of adhesive deposited in the recess 806 can be controlled so that when the first structure 804 is coupled to another structure, the adhesive does not leak onto any surface of the first structure 804 when a protrusion of the other structure is inserted into the recess 806.

[0077] Reference Figure 8C , a fast-cure adhesive robot 818 (e.g., robot 115) can be connected to a fast-cure adhesive applicator 820 or other similar tool. Illustratively, the distal end of the robotic arm of the fast-cure adhesive robot 818 can be connected to the fast-cure adhesive applicator 820, which can be built into the distal end of the robotic arm (where the proximal end of the robotic arm is connected to the fast-cure adhesive robot 818) or can be attached to the robotic arm (and can be fixed or removable). The fast-cure adhesive applicator 820 of the fast-cure adhesive robot 818 can be configured to deposit a fast-cure adhesive 822 onto the surface of the structure.

[0078] Rapid-cure adhesive robot 818 can be separate from structural adhesive robot 812. For example, after structural adhesive robot 812 deposits structural adhesive 816 into recess 806, assembly robot 802 can be rotated to face rapid-cure adhesive robot 818. The distal end of the robotic arm of assembly robot 802 can be positioned toward rapid-cure adhesive robot 818, and similarly, the distal end of the robotic arm of rapid-cure adhesive robot 818 can be positioned toward assembly robot 802. Alternatively, structural adhesive robot 812 can be identical to rapid-cure adhesive robot 818. For example, if structural adhesive applicator 814 is removable from the robotic arm of structural adhesive robot 812, the structural adhesive robot can switch structural adhesive applicator 814 with rapid-cure adhesive applicator 820 (e.g., by replacing one applicator or end effector with another applicator or end effector), thereby becoming rapid-cure adhesive robot 818. The structural adhesive robot 812 and / or the rapid cure adhesive robot 818 may alternatively include multiple applicators (built-in or removable) that are configured to separately deposit different types of adhesive, such as the structural adhesive applicator 814 and the rapid cure adhesive applicator 820. Alternatively, where different types of adhesive are combined (e.g., structural and rapid cure adhesives 704), the structural adhesive robot 812 and / or the rapid cure adhesive robot 818 may include a single applicator (built-in or removable) that is configured to deposit the combined adhesive.

[0079] When the first structure 804 is appropriately positioned (e.g., positioned between the two robots 802, 818), the fast-curing adhesive robot 818 can apply a fast-curing adhesive 822 to the first structure 804. Specifically, the fast-curing adhesive robot 818 can deposit the fast-curing adhesive 822 into the groove 806 of the first structure 804. To do this, the fast-curing adhesive robot 818 can move its robotic arm to a position so that the fast-curing adhesive applicator 820 is located above the groove 806 of the first structure 804 and is close enough so that a controlled amount of adhesive can be deposited within a defined area while avoiding deposition of the adhesive on unintended surfaces or portions of unintended surfaces. For example, where the groove 806 includes a first compartment 807 and a second compartment 809, the defined area in which the fast-curing adhesive 822 is deposited may include the second compartment 809 but not the first compartment 807. Alternatively, where the groove 806 includes a single compartment to receive a combination adhesive (e.g., structural and fast-setting adhesive 704), the defined area in which the combination adhesive is deposited may include a single compartment (as a whole). In either case, in such a position, the adhesive application tip of the fast-setting adhesive applicator 820 may be located approximately directly above the groove 806 and may be directed downwardly into the groove 806 (e.g., into the second compartment 809 or the single compartment of the groove).

[0080] When properly positioned, the rapid-cure adhesive robot 818 can cause the rapid-cure adhesive applicator 820 to deposit a controlled amount of adhesive into the recess 806. The controlled amount of adhesive can at least partially fill the recess 806. In some embodiments, the controlled amount of adhesive can completely or nearly completely fill the second compartment 809 of the recess 806. However, the amount of adhesive can be controlled so that the adhesive does not overflow outside the recess 806 and does not overflow onto the first surface of the first structure 804 that defines the recess 806. For example, the amount of adhesive deposited in the recess 806 can be controlled so that when the first structure 804 is coupled to another structure, the adhesive does not leak onto any surface of the first structure 804 when a protrusion of the other structure is inserted into the recess 806.

[0081] Steering Figure 8D, an assembly robot 824 (e.g., robot 109, 111, or key robot 107) can engage a second structure 826 (e.g., second structure 125, 300, 406). Similar to the first structure 804, the second structure 826 can include one or more features capable of coupling the second structure 826 to one or more other structures. In the illustrated embodiment, the second structure 826 can include a groove on a first surface and can include a tongue 828 (e.g., tongue 302) on a second surface. The first surface and the second surface of the second structure 826 can each lie on respective planes that are substantially perpendicular to each other, and thus, the tongue 828 can be at an angle of approximately 90 degrees to the groove.

[0082] The second structure 826 can be located on the part table 808, and the assembly robot 824 can be positioned relatively close to the part table 808. In such a position, the robotic arm of the assembly robot 824 can be within a proximal range of at least a portion of the part located on the part table 808. Figure 8D In an example embodiment, assembly robot 824 can be located on one side of part table 808, and tongue 828 of second structure 826 can be positioned toward a side of part table 808 that is opposite the side on which assembly robot 824 is located. In this position, the groove of second structure 826 can be oriented at an angle of approximately 90 degrees to assembly robot 824.

[0083] The assembly robot 824 can be connected to an end effector 830. Illustratively, the distal end of the robotic arm of the assembly robot 824 can be connected to the end effector 830, which can be built into the distal end of the robotic arm (where the proximal end of the robotic arm is connected to the assembly robot 824) or can be attached to the robotic arm (and can be fixed or removable). The end effector 830 of the assembly robot 824 can be configured to engage (e.g., pick up) and hold one or more structures. For example, the end effector 830 of the assembly robot 824 can be configured to engage with different structures without a clamp, such as via one or more features of the different structures. Some examples of such an end effector can include a clamp or a gripper.

[0084] The assembly robot 824 can engage the second structure 826 at a third surface of the second structure 826, for example, at angles of approximately 90 degrees and 180 degrees, respectively, to the groove side and the tongue side of the second structure 826. Specifically, the robotic arm of the assembly robot 824 can move to a position where the assembly robot 824 can engage the second structure 826, and then the assembly robot 824 can use the end effector 830 to engage and hold the second structure 826 at the third surface.

[0085] about Figure 8E , assembly robot 824 can be rotated to face assembly robot 802, and assembly robot 802 can be rotated to face assembly robot 824. The distal end of the robotic arm of assembly robot 824 can be positioned toward assembly robot 802, and, similarly, the distal end of the robotic arm of assembly robot 802 can be positioned toward assembly robot 824.

[0086] exist Figure 8E In the example position shown, assembly robot 824 can move second structure 826 to a position where second structure 826 is approximately between assembly robot 824 and assembly robot 802. Additionally, assembly robot 824 can orient second structure 826 such that tongue 828 of second structure 826 faces generally downward, such as by moving a robotic arm of assembly robot 824 and / or an end effector 830 of assembly robot 824 such that second structure 826 is oriented generally downward.

[0087] In some embodiments, the assembly robot 824 can move the second structure 826 according to one or more vectors, which can be based on a CAD model. Each of the one or more vectors can indicate the magnitude (e.g., distance) and direction of movement of the second structure 826 by the assembly robot 824. Each vector can be intended to bring the second structure 826 into the proximal side of the joint, although some vectors can be intermediate vectors intended to bring the second structure 826 to a position where the vectors coupling the first mechanism 804 and the second structure 826 can be applied.

[0088] Assembly robot 802 can position first structure 804 relatively closer to assembly robot 802 than assembly robot 824. In some embodiments, assembly robot 802 can position first structure 804 at least partially above at least a portion of second structure 826. For example, assembly robot 802 can hold first structure 804 at a generally overhead position.

[0089] Reference Figure 8F, assembly robot 802 and assembly robot 824 can respectively move first structure 804 and second structure 826 to a position close to each other. For example, first structure 804 can be positioned below second structure 826 so that first structure 804 and second structure 826 at least partially overlap in an elevational plane (or vertical space). Assembly robot 802 can orient first structure 804 so that groove 806 of first structure 804 faces generally upward, having a controlled amount of structural adhesive 816 and fast-curing adhesive 822 (or combination adhesive) previously deposited therein. For example, assembly robot 802 can move a robotic arm of assembly robot 802 and / or an end effector 810 of assembly robot 802 so that groove 806 of first structure 804 is oriented generally upward. Thus, groove 806 of first structure 804 can face tongue 828 of second structure 826. Similar to the movement of the second structure 826 by the assembly robot 824, the assembly robot 802 can move the first structure 804 according to one or more vectors that can be based on the CAD model. The assembly robot 824 can maintain the second structure 826 in the aforementioned position, with the tongue 828 of the second structure 826 generally oriented downward; although due to the movement of the first structure 804 caused by the assembly robot 802, the second structure 826 can now be positioned above the first structure 804.

[0090] To bring the first structure 804 and the second structure 826 into the proximal range of coupling, one or both of the first structure and / or the second structure can be moved by one or both of the assembly robots 802, 824, respectively. For example, the assembly robot 802 can move the distal end of its robotic arm (at which the first structure 804 is engaged) in a generally upward direction toward the second structure 826. Additionally or alternatively, the assembly robot 824 can move the distal end of its robotic arm (at which the second structure 826 is engaged) in a generally downward direction toward the first structure 804.

[0091] In various embodiments, an MMC program may be used to implement a joint structure for robotic joining in the fixtureless assembly system 800. The MMC program may use a metrology system 831 (e.g., metrology system 131), which may be configured to determine (e.g., detect, calculate, measure, capture, etc.) position data associated with the fixtureless assembly unit 105. Figure 8FIn the context of , metrology system 831 can determine positional data associated with at least one of first structure 804 and / or second structure 826. For example, metrology system 831 can determine a set of coordinates associated with first structure 804. The set of coordinates can indicate the physical position of first structure 804 within fixtureless assembly cell 105 and / or relative to the near side of the joint or second structure 826. Metrology system 831 can provide the positional data to computing system 129. Computing system 129 can receive the positional data and, based on the positional data, can determine a set of corrective actions to be applied so that first structure 804 can be brought into the near side of the joint and joined to second structure 826. For example, computing system 129 can determine the difference between the set of coordinates associated with first structure 804 and the near side of the joint. Computing system 129 can provide the set of corrective actions to a controller communicatively coupled to assembly robot 802, such as by issuing a set of commands to the controller. The controller may apply the set of commands by controlling the robotic arms of the assembly robot 802 according to a set of corrective operations indicated by the set of commands.

[0092] When the structures are within the proximal side of the joint, at least a portion of one structure overlaps with at least a portion of the other structure in at least one of an azimuthal (or horizontal) plane and / or an elevational plane. Based on this overlap, one or more features of one structure can connect with one or more complementary features of the other structure, such as by interlocking or fitting together, such as when a protrusion of one structure is inserted into a recess of the other structure. In the illustrated example operation of the fixtureless assembly system 100, when the first structure 804 and the second structure 826 are within the proximal side of the joint, the tongue 828 of the second structure 826 can be positioned within the groove 806 of the first structure 804, thereby forming a tongue-and-groove joint.

[0093] In some embodiments, the tongue 828 of the second structure 826 may not contact the first structure 804 at the proximal side of the joint. In other words, the robot may be controlled to bring the structures into the proximal side of the joint while preventing the structures from contacting each other. For example, the tongue 828 of the second structure 826 may be located within the groove 806 of the first structure 804, but because the tongue is inserted into the groove without contacting the sides and the bottom, a lateral bonding gap between the tongue and the sides of the groove and a vertical bonding gap between the tongue and the bottom of the groove may result. In contrast, when the first structure 804 and the second structure 826 are located at the proximal side of the joint, the tongue 828 of the second structure 826 may only contact the adhesive deposited in the groove 806 of the first structure 804. For example, as Figure 8FAs shown, tongue 828 can include a plurality of segments 832 (e.g., plurality of segments 304) that contact the rapid curing adhesive 822 within the second compartment 809 of groove 806, while the remainder of the tongue can contact the structural adhesive 816 within the first compartment 807 of groove 806. However, in some further embodiments, the surface of groove 806 surrounding the first structure 804 can contact the surface of tongue 828 surrounding the second structure 826.

[0094] Reference Figure 8G , the assembly robots 802, 824 can remain in their respective positions so that the second structure 826 and the first structure 804 are joined at the proximal side of the joint. While maintaining this positioning, the EM radiation source 834 can be configured to join the first structure 804 and the second structure 826 when joined. For example, the EM radiation source 834 can be configured to apply UV light or other EM radiation 836 to cure the fast-cure adhesive 822, thereby joining the first structure 804 and the second structure 826. The bond created by the EM radiation source 834 can be temporary, while the structural adhesive 816 can provide a permanent bond when cured. In one example, the EM radiation source 834 can be connected to a UV robot 838 (e.g., robot 115, which can be the same as the fast-cure adhesive robot 818 or can be a different robot). For example, as Figure 8G As shown, the EM radiation source 834 can be fixedly or removably attached to the distal end of the robotic arm of the UV robot 838 as an end effector (e.g., a UV light applicator or other curing device). Although the following description relates to this example in which the EM radiation source 834 is connected to the UV robot 838, the EM radiation source 834 is not limited thereto. For example, the EM radiation source 834 may not be attached to the robot, but may be separately positioned or mounted anywhere within the assembly cell 105 (e.g., positioned or mounted on a wall, ceiling, etc.). In this case, the assembly robots 802, 824 can bring the first structure 804 and the second structure 826 into the proximity of the EM radiation source 834 to join the coupled structures.

[0095] UV robot 838 can be positioned relatively close to assembly robot 824 and assembly robot 802. The distal end of the robotic arm of UV robot 838 can be positioned toward first structure 804 and second structure 826, and more specifically, toward the point where first structure 804 and second structure 826 are joined (e.g., toward the tongue-and-groove joint). In this position, the distal end of the robotic arm of UV robot 838 can be located between assembly robot 824 and assembly robot 802.

[0096] The distal end of the robotic arm of the UV robot 838 can be positioned so that the EM radiation source 834 connected to the UV robot 838 is proximal to the point where the first structure 804 and the second structure 826 are joined. For example, the robotic arm of the UV robot 838 can be positioned so that the EM radiation source is positioned at a distance from the tongue-and-groove joint (formed by joining the first structure 804 and the second structure 826 at the proximal side of the joint) that is suitable for receiving the EM radiation 836 at the tongue-and-groove joint. At this suitable distance, the UV robot 838 can emit EM radiation 836 toward the tongue-and-groove joint formed by joining the first structure 804 and the second structure 826.

[0097] The UV robot 838 can position the EM radiation source 834 at a distance from the fast-cure adhesive 822 that is suitable for curing the fast-cure adhesive. With the EM radiation source 834 at this distance, the UV robot 838 (e.g., the computing system 129 or controller of the UV robot 838) can cause the EM radiation source 834 to cure the fast-cure adhesive or other temporary adhesive. For example, the UV robot 838 can cause the EM radiation source 834 to emit UV light or other EM radiation for a period of time sufficient to cure the UV adhesive. However, the UV robot 838 may not cure the structural adhesive, for example, because the structural adhesive may not be cured by exposure to UV light. Therefore, in the case of Figure 8G In one example shown, when first structure 804 and second structure 826 are coupled, UV robot 838 can emit EM radiation 836 into recess 806 through window 811 to cure fast-cure adhesive 822 within second compartment 809. Alternatively, in another example where recess 806 includes a single compartment and contains a combined structural and fast-cure adhesive, UV robot 838 can emit EM radiation 836 into recess 806 through window 811 to cure exposed portions of the combined adhesive through the window within the single compartment. Similarly, where EM radiation source 834 is not attached to the UV robot but is located elsewhere in assembly cell 105, computing system 129 can cause EM radiation source 834 to cure the fast-cure adhesive when the first and second structures are proximate to the EM radiation source, as described above.

[0098] Once the fast-curing adhesive is cured, the UV robot 838 can move its robotic arm away from the first structure 804 and the second structure 826. The first structure 804 and the second structure 826 can be at least temporarily bonded by the cured fast-curing adhesive. However, the structural adhesive (applied by the structural adhesive robot 812, as described above) Figure 8B shown) may still not be cured at this stage.

[0099] at last, Figure 8HIt is shown that assembly robot 824 may remain in its position and may continue to hold second structure 826. At this stage, second structure 826 may be at least temporarily bonded to first structure 804, such as by a cured fast-setting adhesive within recess 806 of the first structure.

[0100] Assembly robot 802 may be separated from first structure 804. For example, assembly robot 802 may disengage its end effector from first structure 804, such as by opening a clamp of end effector 810, releasing end effector 810 from one or more features of first structure 804, and / or otherwise causing end effector 810 to release first structure 804.

[0101] Once separated from first structure 804, assembly robot 802 can move its robotic arm away from first structure 804. For example, assembly robot 802 can retract its robotic arm away from assembly robot 824. Doing so can provide assembly robot 824 with a larger area to move.

[0102] When the assembly robot 802 is separated from the first structure 804, the assembly robot 824 can retain the first structure 804, for example, by retaining the second structure 826 that is at least temporarily bonded to the first structure 804. The cured fast-setting adhesive can provide sufficient bonding to support its retention of the first structure 804 bonded to the second structure 826, even if the assembly robot 824 does not directly retain the first structure 804 (e.g., when the end effector 830 of the assembly robot 824 engages the second structure 826). When joined (even temporarily), the first structure 804 and the second structure 826 can be one structure and / or can be referred to as a subassembly 840. The assembly robot 824 can then retain the subassembly 840 or move the subassembly to another robot (such as the key robot 107). Alternatively, the assembly robot 824 can be the key robot 107.

[0103] Example operation of the robotic repeatable fixtureless assembly system 100, 800 (similar to the above Figures 8A to 8H) to assemble one or more subassemblies, each of which is at least a portion of a vehicle, such as a frame, chassis, body, panel, etc., without jigs. During example operations, while assembly robots 802, 824 (and / or other assembly robots) engage and hold other structures, key robot 107 can continuously hold the subassembly, structural adhesive robot 812 applies structural adhesive 816 to each of the other structures, rapid cure adhesive robot 818 applies rapid cure adhesive 822 to each of the other structures, assembly robots 802, 824 (and / or other assembly robots) couple each of the other structures to the subassembly held by key robot 107, UV robot 838 applies and cures the rapid cure adhesive to at least temporarily bond each of the other structures coupled to the subassembly, and then, after the rapid cure adhesive or other temporary adhesive cures, the assembly robot releases each of the other structures. Multiple subassemblies can be coupled and temporarily bonded to form an assembly, which can then be moved to an oven or otherwise held at a certain temperature for a period of time to cure structural adhesive 816 and permanently bond the structures.

[0104] about Figure 9 , a block diagram illustrates an embodiment of a processing system 900. The processing system 900 may include at least one controller associated with at least one robot. For example, referring to Figure 1 , the processing system 900 can be an embodiment of at least one of the controllers 137 , 139 , 141 , 143 , 145 , 147 associated with at least one of the robots 107 , 109 , 111 , 113 , 115 , 117 .

[0105] The processing system 900 may include various types of machine-readable media and interfaces. As shown, the system 900 includes at least one interconnect 920 (e.g., at least one bus), a permanent storage device 922, a random access memory (RAM) 924, at least one controller interface 926, a read-only memory (ROM) 928, at least one processor 930, and a network component 932.

[0106] The interconnect 920 may communicatively couple components and / or devices collocated with the system 900, such as internal components and / or internal devices within a housing of the system 900. For example, the interconnect 920 may communicatively couple the processor 930 with the persistent storage 922, the RAM 924, and / or the ROM 928. The processor 930 may be configured to access and load computer-executable instructions from at least one of the persistent storage 922, the RAM 924, and / or the ROM 928.

[0107] Persistent storage 922 may be nonvolatile memory that stores instructions and data independent of the power state (eg, on or off) of system 900. For example, persistent storage 922 may be a hard drive, flash drive, or other read / write memory device.

[0108] ROM 928 can store static instructions that implement the basic functionality of system 900 and the components therein. For example, ROM 928 can store instructions for processor 930 to execute a set of processes associated with a robot of at least a portion of a vehicle, such as those described above with respect to one or more of the robots. Examples of ROM 928 can include erasable programmable ROM (EPROM) or electrical EPROM (EEPROM), compact disc ROM (CD-ROM) or other optical disc storage, magnetic disc storage or other magnetic storage, and / or other computer-accessible and computer-readable media that can store program code as instructions and / or data structures.

[0109] RAM 924 may include volatile read / write memory. RAM 924 may store computer executable instructions associated with the run-time operation of processor 930. In addition, RAM 924 may store real-time data captured during the assembly of at least a portion of the vehicle, for example, as described above with respect to Figure 1 and Figures 8A-8H One or more of the above.

[0110] The processor 930 may be implemented as one or more general and / or special purpose processors. Examples of general and / or special purpose processors may include microprocessors, microcontrollers, DSP processors, and / or any other suitable circuit configured to execute instructions loaded from at least one of the permanent storage device 922, RAM 924, and / or ROM 928. Alternatively or additionally, the processor 930 may be implemented as dedicated hardware, such as at least one field programmable gate array (FPGA), at least one programmable logic device (PLD), at least one controller, at least one state machine, a set of logic gates, at least one discrete hardware component, or any other suitable circuit and / or combination thereof.

[0111] The interconnect 920 can further communicatively connect the system 900 to one or more controller interfaces 926. For example, during assembly of at least a portion of a vehicle, the controller interface 926 can communicatively connect the system 900 to various circuits associated with one or more robots. Instructions executed by the processor 930 can cause instructions to be communicated to the robots via the controller interface 926, which can cause the robots to move and / or perform other actions associated with assembly of at least a portion of the vehicle. For example, instructions executed by the processor 930 can cause signals to be sent via the controller interface 926 to circuits and / or other machinery of the robots to direct the robots to move and / or perform other actions associated with assembly of at least a portion of the vehicle.

[0112] In some embodiments, system 900 may include a network component 932. Network component 932 may be configured to communicate, for example, over a network to send and / or receive instructions associated with assembly of at least a portion of a vehicle. Instructions communicated over the network by network component 932 may include instructions associated with assembly of at least a portion of the vehicle and may be communicated before, during, and / or after assembly of at least a portion of the vehicle. Examples of networks over which network component 932 may communicate may include a local area network (LAN), a wide area network (WAN), the Internet, an intranet, or another wired or wireless network.

[0113] Various aspects described herein may be implemented, at least in part, as software processes in a computer programming product. These processes may be specified as a set of instructions recorded on a machine-readable storage medium. When a set of instructions is executed by the processor 930, the set of instructions may cause the processor to perform the operations indicated and recorded in the set of instructions.

[0114] Therefore, in the above reference Figure 1-9In the example of the described fixture-free assembly operation, a first material handling robot (e.g., robot 109, assembly robot 802) holds one of the structures (e.g., first structure 200, 402, 600, 700, 804) including a recess (e.g., recess 202, 602, 702, 806). Then, one or more adhesive dispensing robots (e.g., robot 113, structural adhesive robot 812, and / or rapid-cure adhesive robot 818) fill the recess with structural adhesive 604, 816 (e.g., in compartments 608, 807) and the recess with rapid-cure adhesive 404, 606, 822 (e.g., in compartments 610, 809), such that the rapid-cure adhesive is inserted into opposing windows 204, 612, 708, 811. Alternatively, a single structural and rapid-cure adhesive 704 can be inserted into the recess (e.g., in compartment 706). Next, a second material handling robot (e.g., robot 111, assembly robot 824) holds another of the structures (e.g., second structure 300, 406, 826) including tongue 302, 828, and the first and second material handling robots position the first and second structures proximal to the joint based on the MMC. Once the optimal position of the structures has been identified by the MMC, the second material handling robot inserts the tongue of the second structure into the fast-cure adhesive within the groove. Once the tongue is inserted, a fast-cure robot (e.g., robot 115, UV robot 838) emits EM radiation 836 (e.g., UV radiation) that enters the groove through the window, causing the fast-cure adhesive (or the exposed portions of the structural and fast-cure adhesives) to cure and rapidly hold the two structures. The robots can then release the joined structures and perform other joining operations while allowing the structural adhesive (or the unexposed portions of the structural and fast-cure adhesives) to cure.

[0115] Thus, the present disclosure increases the likelihood of correctly retaining a structure during a fixture-free assembly process. For example, the retention features of the structure allow a fast-curing adhesive robot to apply a fast-curing adhesive at the time the structural adhesive is applied, rather than applying the fast-curing adhesive afterward during the coupling operation. In this way, the fast-curing adhesive robot can avoid the aforementioned difficulties associated with applying adhesive in a tightly packed area between material handling robots (e.g., obstruction of laser tracking by the fast-curing adhesive robot during MMC). Instead, the fast-curing adhesive robot can apply EM radiation after the structure is positioned to quickly cure the adhesive (e.g., through a window in the groove), thereby improving the efficiency of assembly. In addition, the flexibility of the coupling position can be increased (e.g., including an inverted orientation), thereby allowing for more optimized positioning.

[0116] In addition, the retention features of the structure allow the fast-curing adhesive within the groove to encapsulate the tongue, which provides a double shear retention force that is stronger than the single shear retention force generated by the surface of the groove and the surface of the tongue. The groove and window can also allow the adhesive to be contained to minimize overflow or leakage when inserting the tongue and / or manipulating the structure. Therefore, the possibility of adhesive dripping and structural misalignment can be reduced, thereby minimizing part deflection and falling, for example, in stacked parts. In addition, the tongue can be optimized to minimize overflow and maximize the surface area in contact with the adhesive (for example, through multiple segments or openings in the tongue) to maximize bonding strength and / or optimize printability during additive manufacturing. Therefore, when the structural adhesive cures, the structure can be maintained with acceptable tolerances, thereby reducing retention failure and improving structural integrity. The retention features of the fast-curing adhesive can also be redesigned with different structures, thereby reducing the cycle time for completing the assembly. Therefore, the cycle time of the assembly process, the structural adhesive content, the printability of the parts, the structural quality and the bonding strength can be optimized. Additionally, the visual appeal of the structure may be improved by minimizing the visibility of the fast-setting adhesive after it has been applied (eg, by removing unsightly adhesive lines or globs).

[0117] The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to the exemplary embodiments presented in this disclosure will be apparent to those skilled in the art. Accordingly, the claims are not intended to be limited to the exemplary embodiments presented throughout this disclosure, but are to be given the full scope consistent with the language of the claims. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or later become known to those of ordinary skill in the art are intended to be covered by the claims. Furthermore, nothing disclosed herein is intended to be dedicated to the public, regardless of whether such disclosure is expressly recited in the claims. No claim element shall be construed under 35 U.S.C. § 112(f) or similar law in an applicable jurisdiction unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”

Claims

1. A device comprising: a first structure comprising a recess and at least one window configured to allow electromagnetic (EM) radiation to enter the recess; a second structure comprising a retaining feature; wherein the recess of the first structure receives at least one adhesive to couple the first structure to the second structure and includes a depression to receive a retention feature of the second structure; wherein the at least one adhesive cures at a first rate when exposed to one of time or heat, and wherein the at least one adhesive cures at a second rate faster than the first rate when exposed to the electromagnetic (EM) radiation; and Wherein, the at least one window includes a screen.

2. The device according to claim 1, wherein The electromagnetic (EM) radiation includes ultraviolet (UV) radiation.

3. The device according to claim 1, wherein The at least one adhesive includes a first adhesive that cures at the first rate and a second adhesive that cures at the second rate.

4. The device according to claim 3, wherein The recess includes a plurality of compartments, and the first adhesive and the second adhesive are contained within separate compartments of the plurality of compartments.

5. The apparatus according to claim 3, wherein The second adhesive is filled in the groove before coupling the first structure to the second structure.

6. The apparatus according to claim 1, wherein The second structure includes a tongue that contacts the at least one adhesive and couples the second structure to the first structure.

7. The apparatus according to claim 6, wherein The tongue includes a plurality of segments spaced apart from each other, and each segment is inserted into the at least one adhesive.

8. The apparatus according to claim 6, wherein The tongue includes a plurality of openings that are inserted into the at least one adhesive.

9. An assembly system comprising: a first material handling robot configured to hold a first structure comprising a recess and at least one window configured to allow electromagnetic (EM) radiation to enter the recess; a second structure comprising a retaining feature; wherein the recess of the first structure receives at least one adhesive to couple the first structure to the second structure and includes a depression to receive a retention feature of the second structure; an electromagnetic (EM) radiation source configured to emit EM radiation into the recess; wherein the at least one adhesive cures at a first rate when exposed to one of time or heat, and wherein the at least one adhesive cures at a second rate faster than the first rate when exposed to the electromagnetic (EM) radiation; and Wherein, the at least one window includes a screen.

10. The assembly system according to claim 9, wherein: The first structure includes at least one window that receives the electromagnetic (EM) radiation into the recess to cure the at least one adhesive at the second rate.

11. The assembly system according to claim 9 further includes a second material handling robot, wherein the second material handling robot is configured to hold a second structure including a tongue, and the second material handling robot is further configured to insert the tongue into the at least one adhesive to connect the first structure to the second structure.

12. The assembly system of claim 9, further comprising a rapid curing robot comprising the electromagnetic (EM) radiation source.

13. The assembly system of claim 9, further comprising an adhesive dispensing robot configured to fill the at least one adhesive into the recess.

14. The assembly system according to claim 13, wherein: The at least one adhesive includes a first adhesive that cures at the first rate and a second adhesive that cures at the second rate.

15. The assembly system of claim 14, wherein: The recess includes a plurality of compartments, and wherein the adhesive dispensing robot is configured to fill individual compartments of the plurality of compartments with the first adhesive and the second adhesive.

16. The assembly system of claim 14, further comprising a second material handling robot configured to insert a tongue of the second structure into the second adhesive to couple the first structure to the second structure.

17. An apparatus comprising: a first structure comprising a recess for receiving at least one adhesive; and a second structure coupled to the first structure, the second structure comprising a tongue contacting the at least one adhesive; wherein the groove of the first structure comprises a depression sized to receive the tongue of the second structure; wherein the at least one adhesive is configured to cure at a first rate when exposed to one of time or heat, and wherein the at least one adhesive is configured to cure at a second rate faster than the first rate when exposed to electromagnetic (EM) radiation; and Wherein, the first structure comprises at least one window configured to allow electromagnetic (EM) radiation to enter the recess to cure the at least one adhesive at a second rate, wherein the at least one window comprises a screen.

18. The apparatus according to claim 17, wherein The first structure includes at least one window configured to allow the electromagnetic (EM) radiation to enter the recess to cure the at least one adhesive at the second rate.

19. The apparatus according to claim 17, wherein The groove comprises a plurality of compartments, wherein the at least one adhesive comprises a first adhesive that cures at the first rate within a first compartment of the plurality of compartments, and wherein the at least one adhesive comprises a second adhesive that cures at the second rate within a second compartment of the plurality of compartments.

20. The apparatus of claim 17, wherein: The tongue includes one of a waffle shape, a fork shape, a comb shape, a ring shape, or a snake shape.

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