System and method for configuring a plant assembly station

Abstract

Methods and systems are provided for configuring a plant assembly station at a vehicle manufacturing plant. Factory sensor data generated by a factory sensor system is received at a factory assembly configuration system. The plant sensor data is associated with a configuration of a first plant assembly station at the vehicle manufacturing plant. A digital twin of the first plant assembly station is generated based in part on the plant sensor data. Based on a simulation-based evaluation of the digital twinning of the first plant assembly station, it is determined whether the configuration of the first plant assembly station complies with an operational rule. An operability state of the configuration of the first plant assembly station is generated based on the determination.

Description

Technical Field

[0001] The technical field relates generally to vehicles and, more particularly, to systems and methods for configuring a factory assembly station. Background Art

[0002] A vehicle manufacturing plant typically includes multiple factory assembly stations. Factory assembly stations are often reconfigured to accommodate changes in the production of different vehicle product types. Examples of vehicle product types include, but are not limited to, sedans and pickup trucks. A vehicle product type may be a specific vehicle model. In many cases, when a vehicle manufacturing plant changes the vehicle product type to be produced, the vehicle manufacturing plant may be shut down for an extended period of time while the factory assembly stations are reconfigured to support the production of that vehicle product type.

[0003] Accordingly, it is desirable to provide improved methods and systems for configuring factory assembly stations.Other desirable features and characteristics will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background. Summary of the invention

[0004] In various embodiments, a factory assembly station configuration system includes at least one processor and at least one memory communicatively coupled to the at least one processor. The at least one memory includes instructions that, when executed by the at least one processor, cause the at least one processor to: receive factory sensor data generated by a factory sensor system, the factory sensor data being associated with a configuration of a first factory assembly station at a vehicle manufacturing plant; generate a digital twin of the first factory assembly station based in part on the factory sensor data; determine whether the configuration of the first factory assembly station complies with an operating rule based on a simulation-based evaluation of the digital twin of the first factory assembly station; and generate an operability status of the configuration of the first factory assembly station based on the determination.

[0005] In at least one embodiment, the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: receive a vehicle product type from a factory operating system; and generate a digital twin of the first factory assembly station based in part on the vehicle product type.

[0006] In at least one embodiment, the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: receive factory sensor data generated by a factory sensor system, the factory sensor data being associated with the location of at least one factory structure; and generate a digital twin of a first factory assembly station based in part on the location of the at least one factory structure.

[0007] In at least one embodiment, the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: receive factory sensor data generated by a factory sensor system, the factory sensor data being associated with the location of at least one fixed asset of a first factory assembly station at a vehicle manufacturing plant; and generate a digital twin of the first factory assembly station based in part on the location of the at least one fixed asset of the first factory assembly station.

[0008] In at least one embodiment, the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: send the digital twin of the first factory assembly station to a factory operating system to enable the factory operating system to send instructions to a plurality of self-mobile assets of the first factory assembly station to move to locations within the vehicle manufacturing plant based on the digital twin of the first factory assembly station.

[0009] In at least one embodiment, each of the plurality of self-mobile assets is one of: an autonomous mobile robot (AMR) with factory equipment, an AMR with parts, an AMR crane, an AMR with kitted parts, and an AMR with station lighting.

[0010] In at least one embodiment, the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: receive factory sensor data generated by a factory sensor system, the factory sensor data being associated with modifications to at least one asset at the first factory assembly station; and generate a digital twin of the first factory assembly station based on the modifications to at least one asset at the first factory assembly station.

[0011] In at least one embodiment, the modification of at least one asset includes one of: an asset orientation change, an asset position change, swapping a position of a first asset with a position of a second asset, an asset replacement, an asset addition, and an asset removal.

[0012] In at least one embodiment, modification of at least one asset is accomplished via instructions provided by a human worker to at least one self-mobile asset of a first factory assembly station to move to a location within the vehicle manufacturing plant.

[0013] In at least one embodiment, the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: receive factory sensor data generated by a factory sensor system, the factory sensor data being associated with a configuration of a plurality of factory assembly stations at a vehicle manufacturing plant, the plurality of factory assembly stations including a first factory assembly station; generate a digital twin of the vehicle manufacturing plant including a plurality of digital twins of the plurality of factory assembly stations based on the factory sensor data; determine whether the configuration of the vehicle manufacturing plant complies with operating rules based on a simulation-based evaluation of the digital twin of the vehicle manufacturing plant; and send the digital twin of the vehicle manufacturing plant to a factory operating system to enable the factory operating system to send configuration commands to a plurality of self-mobile assets at the plurality of factory assembly stations to move to locations within the vehicle manufacturing plant according to the digital twin of the vehicle manufacturing plant.

[0014] In at least one embodiment, the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: send the digital twin of the first factory assembly station to a factory operating system to enable the factory operating system to send a component setting to at least one component of the factory assembly station based on the digital twin of the first factory assembly station.

[0015] In at least one embodiment, at least one of the plurality of components of a factory assembly station includes station lighting, station equipment, and station tooling.

[0016] In at least one embodiment, the configuration of a first factory assembly station at a vehicle manufacturing plant is associated with a relocation of the first factory assembly station from a first location within the vehicle manufacturing plant to a second location within the vehicle manufacturing plant.

[0017] In at least one embodiment, the configuration of the first factory assembly station of the vehicle manufacturing plant is one of a configuration of a new factory assembly station and a reconfiguration of an existing factory assembly station.

[0018] In various embodiments, a method for configuring a factory assembly station includes: receiving factory sensor data generated by a factory sensor system, the factory sensor data being associated with a configuration of a first factory assembly station at a vehicle manufacturing plant; generating a digital twin of the first factory assembly station based in part on the factory sensor data; determining whether the configuration of the first factory assembly station complies with operating rules based on a simulation-based evaluation of the digital twin of the first factory assembly station; and generating an operability status of the configuration of the first factory assembly station based on the determination.

[0019] In at least one embodiment, the method further includes sending the digital twin of the first factory assembly station to a factory operating system to enable the factory operating system to send instructions to a plurality of self-mobile assets of the first factory assembly station to move to locations within the vehicle manufacturing plant in accordance with the digital twin of the first factory assembly station.

[0020] In at least one embodiment, the method also includes: receiving factory sensor data generated by a factory sensor system, the factory sensor data being associated with a modification of at least one asset of the first factory assembly station; and generating a digital twin of the first factory assembly station based on the modification of at least one asset at the first factory assembly station, wherein the modification of at least one asset includes one of: a change in asset orientation, a change in asset position, swapping the position of a first asset with the position of a second asset, asset replacement, asset addition, and asset removal.

[0021] In at least one embodiment, the method also includes: receiving factory sensor data generated by a factory sensor system, the factory sensor data associated with a modification of at least one asset of the first factory assembly station; and generating a digital twin of the first factory assembly station based on the modification of at least one asset at the first factory assembly station, wherein the modification of the at least one asset is achieved via instructions provided by a human worker to at least one self-mobile asset of the first factory assembly station to move to a location within the vehicle manufacturing plant.

[0022] In at least one embodiment, the method further includes sending the digital twin of the first factory assembly station to a factory operating system to enable the factory operating system to send component settings to at least one component of the factory assembly station based on the digital twin of the first factory assembly station, wherein at least one of the plurality of components of the factory assembly station is station lighting, station equipment, and station tooling.

[0023] In various embodiments, a vehicle manufacturing plant includes a plurality of factory assembly stations, a factory sensor system, and a factory assembly station configuration system. A factory assembly station configuration system includes at least one processor and at least one memory communicatively coupled to the at least one processor. The at least one memory includes instructions that, when executed by the at least one processor, cause the at least one processor to: receive factory sensor data generated by the factory sensor system, the factory sensor data being associated with a configuration of a first factory assembly station among a plurality of factory assembly stations at the vehicle manufacturing plant; generate a digital twin of the first factory assembly station based in part on the factory sensor data; determine whether the configuration of the first factory assembly station complies with an operating rule based on a simulation-based evaluation of the digital twin of the first factory assembly station; and generate an operability state of the configuration of the first factory assembly station based on the determination. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Exemplary embodiments will be described below with reference to the following drawings, wherein like reference numerals denote like elements, and in the drawings:

[0025] Figure 1 is a functional block diagram of a vehicle manufacturing plant including a factory assembly station configuration system according to at least one embodiment;

[0026] Figure 2 is a functional block diagram of a factory assembly station configuration system according to at least one embodiment;

[0027] Figure 3 is a flowchart representation of a method of configuring a factory assembly station via instructions provided by a human worker to a self-mobile asset in accordance with at least one embodiment;

[0028] Figure 4 is a flowchart representation of a method of automatically configuring a factory assembly station for providing instructions to a self-mobile asset via a factory operating system in accordance with at least one embodiment; and

[0029] Figure 5 is a schematic diagram of examples of different levels of reconfiguration of a factory assembly plant that can be facilitated by a factory assembly station configuration system in accordance with at least one embodiment. DETAILED DESCRIPTION

[0030] The following detailed description is merely exemplary in nature and is not intended to limit application and use. In addition, it is not intended to be bound by any express or implied theory presented in the aforementioned technical field, background technology, summary of the invention or the following detailed description. As used herein, the term module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated or group) and memory that executes one or more software or firmware programs, a combinational logic circuit and / or other suitable components that provide the described functions.

[0031] Embodiments of the present disclosure may be described herein in terms of functional and / or logical block components and various processing steps. It should be understood that such block components may be implemented by any number of hardware, software, and / or firmware components configured to perform a specified function. For example, embodiments of the present disclosure may employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, etc., which may perform various functions under the control of one or more microprocessors or other control devices. In addition, those skilled in the art will appreciate that embodiments of the present disclosure may be practiced in conjunction with any number of systems, and the systems described herein are merely exemplary embodiments of the present disclosure.

[0032] For the sake of brevity, conventional techniques related to signal processing, data transmission, signaling, control, and other functional aspects of the system (and the individual operating components of the system) may not be described in detail herein. In addition, the connecting lines shown in the various figures included herein are intended to represent exemplary functional relationships and / or physical connections between the various elements. It should be noted that there may be many alternative or additional functional relationships or physical connections in the embodiments of the present disclosure.

[0033] refer to Figure 1 , a functional block diagram of a vehicle manufacturing plant 100 including a factory assembly station configuration system 102 is shown according to at least one embodiment. The vehicle manufacturing plant 100 includes a factory assembly station 104, a factory operating system 106, a factory sensor system 108, and a factory assembly station configuration system 102. Although the vehicle manufacturing plant 100 is shown as including a single factory assembly station 104, the vehicle manufacturing plant 100 typically includes multiple factory assembly stations 104. When a vehicle 110 is assembled at the vehicle manufacturing plant 100, different factory assembly stations 104 are configured to install different components in the vehicle 110. The factory assembly station 104 is configured for the production of a specific vehicle product type. Examples of vehicle product types include, but are not limited to, sedans and pickup trucks. In various embodiments, the vehicle product type specifies a vehicle model.

[0034] Multiple vehicles 110 may be assembled at the vehicle manufacturing plant 100 at the same time. Different vehicles 110 may be simultaneously undergoing installation of different vehicle components at different factory assembly stations 104. Each of the vehicles 110 may be at a different point in the vehicle assembly process. The factory operating system 106 is configured to coordinate the manufacture of the vehicles 110 at the vehicle manufacturing plant 100. The factory operating system 106 is configured to coordinate the configuration / reconfiguration of different factory assembly stations 104 at the vehicle manufacturing plant 100 to assemble vehicles 110 of a specific vehicle product type.

[0035] Although a single centralized factory operating system 106 is shown, the vehicle manufacturing plant 100 may include multiple distributed factory operating systems that coordinate the assembly of vehicles 110 at the vehicle manufacturing plant 100. For example, the factory operating system 106 may include a factory control tower that communicates with multiple factory floor systems to coordinate the configuration / reconfiguration of factory assembly stations 104 at the vehicle manufacturing plant 100. The factory operating system 106 is communicatively coupled to the factory assembly station configuration system 102.

[0036] The factory sensor system 108 includes a plurality of factory sensors distributed throughout the vehicle manufacturing plant 100. An example of a factory sensor is a camera. The factory sensor system 108 is configured to generate factory sensor data associated with the configuration of one or more factory assembly stations 104 in the vehicle manufacturing plant 100. The factory sensor system 108 is communicatively coupled to the factory assembly station configuration system 102.

[0037] The factory assembly station 104 includes a plurality of self-moving assets and one or more fixed assets. Examples of self-moving assets include, but are not limited to, autonomous mobile robots (AMRs) 112A, 112B with equipment, AMRs 114 with cranes, AMRs 116 with matching parts, AMRs 118 with lighting equipment, and AMRs 120 with parts. An example of a fixed asset is fixed equipment 122. The vehicle manufacturing plant 100 may include one or more factory structures 124. The positioning of the self-moving assets in the configuration of the factory assembly station 104 is based on the location of the fixed equipment 122 and / or one or more factory structures 124. Different factory assembly stations 104 at the vehicle manufacturing plant 100 may have different configurations.

[0038] The factory assembly station configuration system 102 is configured to receive factory sensor data generated by the factory sensor system 108. The factory sensor data is associated with the configuration of the factory assembly station 104. The factory assembly station configuration system 102 is configured to generate a digital twin 104DT of the factory assembly station based on the factory sensor data. The digital twin 104DT of the factory assembly station is a virtual representation of the physical configuration of the factory assembly station 104. The factory sensor system 108 provides a perception infrastructure that operates as a link to mirror the physical configuration of the physical factory assembly station 104 into the digital twin 104DT of the factory assembly station at the factory assembly station configuration system 102. The locations of the self-moving assets 112A, 112B, 114, 116, 118, 120, one or more fixed assets 122 and / or one or more factory structures 124 in the physical factory assembly station 104 are mirrored to the locations of the digital twin representations of the self-moving assets 112ADT, 112B DT, 114DT, 116DT, 118DT, 120DT, fixed assets 122DT and / or factory structures 124DT in the digital twin 104DT of the factory assembly station.

[0039] In at least one embodiment, the factory assembly station configuration system 102 is configured to generate a configuration of a digital twin 104DT of a new factory assembly station. The factory assembly station configuration system 102 is configured to facilitate configuration of a new factory assembly station 104 according to the configuration of the digital twin 104DT of the new factory assembly station based on factory sensor data received from the factory sensor system 108. In at least one embodiment, the factory assembly station configuration system 102 is configured to generate a configuration of a digital twin 104DT of a relocated factory assembly station. The factory assembly station configuration system 102 is configured to facilitate configuration of a relocated factory assembly station 104 according to the configuration of the digital twin 104DT of the relocated factory assembly station based on factory sensor data received from the factory sensor system 108.

[0040] In at least one embodiment, the factory assembly station configuration system 102 is configured to generate a configuration of a digital twin 104DT of a modified factory assembly station. The factory assembly station configuration system 102 is configured to facilitate configuration of the modified factory assembly station 104 according to the configuration of the digital twin 104DT of the modified factory assembly station based on factory sensor data received from the factory sensor system 108. Examples of modifications to the configuration of the factory assembly station 104 include, but are not limited to: asset orientation change, asset position change, swapping the position of a first asset with the position of a second asset, asset replacement, asset addition, and asset removal.

[0041] In various embodiments, the modification of the configuration of the factory assembly station 104 is implemented via instructions provided by a human worker to one or more self-moving assets 112A, 112B, 114, 116, 118, 120 of the factory assembly station 104. In various embodiments, the modification of the configuration of the factory assembly station 104 is implemented via instructions provided by the factory operating system 106 to one or more of the self-moving assets 112A, 112B, 114, 116, 118, 120 of the factory assembly station 104 according to the modified configuration of the digital twin factory assembly station 104DT.

[0042] The factory assembly station configuration system 102 is configured to determine whether the configuration of the factory assembly station 104 complies with the operating rules based on the simulation-based evaluation of the digital twin 104DT of the factory assembly station. The factory assembly station configuration system 102 is configured to generate an operability status of the factory assembly station 104 based on the simulation-based evaluation of the digital twin 104DT of the factory assembly station. If the factory assembly station configuration system 102 determines that the configuration of the factory assembly station 104 complies with the operating rules, the configuration of the factory assembly station 104 is considered to have an operable operability status.

[0043] If the factory assembly station configuration system 102 determines that the configuration of the factory assembly station 104 does not comply with the operating rules, the configuration of the factory assembly station 104 is considered to have an inoperable operability status. The factory assembly station configuration system 102 is configured to evaluate additional modifications to the factory assembly station 104 until the factory assembly station configuration system 102 determines that the configuration of the factory assembly station 104 complies with the operating rules.

[0044] In at least one embodiment, the factory assembly station configuration system 102 is configured to receive factory sensor data generated by a factory sensor system 108. The factory sensor data is associated with the configuration of a plurality of factory assembly stations 104 at the vehicle manufacturing plant 100. The factory assembly station configuration system 102 is configured to generate a digital twin of the vehicle manufacturing plant including a plurality of digital twins 104DT of the plurality of factory assembly stations based on the factory sensor data. The factory assembly station configuration system 102 is configured to determine whether the configuration of the vehicle manufacturing plant complies with operating rules based on a simulation-based evaluation of the digital twin of the vehicle manufacturing plant. The factory assembly station configuration system 102 is configured to send the digital twin of the vehicle manufacturing plant to the factory operating system 106 to enable the factory operating system 106 to send instructions to a plurality of self-mobile assets of each of the plurality of factory assembly stations 104 to move to a location within the vehicle manufacturing plant 100 according to the digital twin of the vehicle manufacturing plant.

[0045] In at least one embodiment, the digital twin 104DT of the factory assembly station generated by the factory assembly station configuration system 102 includes component settings for one or more components of the factory assembly station 104. The factory assembly station configuration system 102 is configured to send the digital twin 104DT of the factory assembly station to the factory operating system 106 to enable the factory operating system 106 to send the component settings to the one or more components of the factory assembly station 104 based on the digital twin 104DT of the first factory assembly station. Examples of components include, but are not limited to, station lighting, station equipment, and station tools.

[0046] refer to Figure 2 , shows a functional block diagram of a factory assembly station configuration system 102 according to at least one embodiment. The factory assembly station configuration system 102 includes at least one processor 200, at least one memory 202, and a communication system 204. The one or more processors 200 are communicatively coupled to the at least one memory 202 and the communication system 204. The one or more processors 200 are programmable devices that include one or more instructions stored in or associated with the at least one memory 202. The at least one memory 202 includes instructions that the one or more processors 200 are configured to execute.

[0047] At least one memory 202 is a computer-readable storage device or medium. One or more processors 200 can be any customized or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), an auxiliary processor in several processors, a semiconductor-based microprocessor (in the form of a microchip or chipset), a macroprocessor, any combination thereof, or any device generally used to execute instructions. For example, a computer-readable storage device or medium may include volatile and non-volatile storage in a read-only memory (ROM), a random access memory (RAM), and a keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operating variables when one or more processors 200 are powered off. The computer-readable storage device or medium can be implemented using any of many known memory devices, such as a PROM (programmable read-only memory), an EPROM (electrical PROM), an EEPROM (electrically erasable PROM), a flash memory, or any other electrical memory device, a magnetic memory device, an optical memory device, or a combined memory device capable of storing data, some of which represent executable instructions used by the factory assembly station configuration system 102. The instructions may include one or more separate programs, each program including an ordered list of executable instructions for implementing logical functions. When executed by one or more processors 200, the instructions perform logic, calculations, methods and / or algorithms for implementing the configuration of the factory assembly station 104.

[0048] The communication system 204 is configured to facilitate communication between the factory assembly station configuration system 102 and the factory operating system 106. The at least one memory 202 includes a factory assembly station digital twin generator 206 and a factory assembly station configuration evaluator 208. The factory assembly station configuration system 102 may include additional elements that facilitate the operation of the factory assembly station configuration system 102.

[0049] refer to Figure 3 , a flowchart representation of a method 300 for configuring a factory assembly station 104 via instructions provided by a human worker to a self-mobile asset 112A, 112B, 114, 116, 118, 120 according to at least one embodiment is shown. The method 300 will be described with reference to an exemplary embodiment of the factory assembly station configuration system 102. As can be understood from this disclosure, the order of operations within the method 300 is not limited to the following. Figure 3 The present invention is not performed in the order shown, but may be performed in one or more different orders according to the present disclosure.

[0050] At 302, the factory operating system 106 identifies a vehicle product type for production at the vehicle manufacturing plant 100. Examples of vehicle product types include, but are not limited to, sedans and pickup trucks. In various embodiments, the vehicle product type specifies a vehicle model. At 304, the factory operating system 106 confirms the availability of resources required to produce the vehicle product type. Examples of resources include, but are not limited to, station equipment, tools, materials, supporting parts, and manpower.

[0051] At 306, the configuration of the factory assembly station 104 is modified via human worker instructions provided to one or more self-mobile assets 112A, 112B, 114, 116, 118, 120 of the factory assembly station 104. Examples of self-mobile assets 112A, 112B, 114, 116, 118, 120 include, but are not limited to, AMRs 112A, 112B with equipment, AMR 114 with a crane, AMR 116 with kitted parts, AMR 118 with lighting, and AMR 120 with parts.

[0052] At 308, the factory assembly station configuration system 102 receives factory sensor data generated by the factory sensor system 108. In at least one embodiment, the factory assembly station digital twin generator 206 receives factory sensor data generated by the factory sensor system 108. The factory sensor system 108 includes a plurality of factory sensors distributed throughout the vehicle manufacturing plant 100. The factory sensor system 108 is configured to generate factory sensor data associated with the configuration of one or more factory assembly stations 104 to the factory assembly station configuration system 102.

[0053] At 310, the factory assembly station configuration system 102 generates a digital twin 104DT of the factory assembly station based on the factory sensor data. In at least one embodiment, the factory assembly station digital twin generator 206 generates the digital twin 104DT of the factory assembly station based on the factory sensor data. The digital twin 104DT of the factory assembly station is a virtual representation of the physical configuration of the factory assembly station 104. The factory sensor system 108 provides a perception infrastructure that operates as a link to mirror the physical configuration of the physical factory assembly station 104 into the digital twin 104DT of the factory assembly station at the factory assembly station configuration system 102.

[0054] At 312, the factory assembly station configuration system 102 determines whether the configuration of the modified factory assembly station 104 complies with the operating rules based on the evaluation of the digital twin 104DT of the factory assembly station. In at least one embodiment, the factory assembly station configuration evaluator 208 determines whether the configuration of the modified factory assembly station 104 complies with the operating rules based on the evaluation of the digital twin 104DT of the factory assembly station. Examples of operating rules include, but are not limited to, safety rules and operating permissions.

[0055] If the factory assembly station configuration system 102 determines that the modified configuration of the factory assembly station 104 does not comply with the operating rules, the factory assembly station configuration system 102 generates an operability status indicating that the factory assembly station 104 is not operable at 314. In at least one embodiment, if the factory assembly station configuration evaluator 208 determines that the modified configuration of the factory assembly station 104 does not comply with the operating rules, the factory assembly station configuration evaluator 208 generates an operability status indicating that the factory assembly station 104 is not operable at 314. The method 300 returns to 306.

[0056] If the factory assembly station configuration system 102 determines that the modified configuration of the factory assembly station 104 complies with the operating rules, the factory assembly station configuration system 102 generates an operability status indicating that the factory assembly station 104 is operable at 316. In at least one embodiment, if the factory assembly station configuration evaluator 208 determines that the modified configuration of the factory assembly station 104 complies with the operating rules, the factory assembly station configuration evaluator 208 generates an operability status indicating that the factory assembly station 104 is operable at 316. Validation of the factory assembly station 104 based on the factory assembly station configuration system's evaluation of the digital twin 104 DT of the factory assembly station is complete, and manufacturing operations for the vehicle product type are commissioned.

[0057] refer to Figure 4 , a flowchart representation of a method 400 for automatically configuring a factory assembly station 104 via instructions provided to a self-mobile asset 112A, 112B, 114, 116, 118, 120 via a factory operating system 106 according to at least one embodiment is shown. The method 400 will be described with reference to an exemplary embodiment of the factory assembly station configuration system 102. As can be understood from this disclosure, the order of operations within the method 400 is not limited to the following. Figure 4 The present invention is not performed in the order shown, but may be performed in one or more different orders according to the present disclosure.

[0058] At 402, the factory operating system 106 identifies a vehicle product type for production at the vehicle manufacturing plant 100. Examples of vehicle product types include, but are not limited to, sedans and pickup trucks. In various embodiments, the vehicle product type specifies a vehicle model. At 404, the factory operating system 106 confirms the availability of resources required to produce the vehicle product type. Examples of resources include, but are not limited to, station equipment, tools, materials, supporting parts, and manpower.

[0059] At 406, the factory assembly station configuration system 102 receives factory sensor data generated by the factory sensor system 108. In at least one embodiment, the factory assembly station digital twin generator 206 receives factory sensor data generated by the factory sensor system 108. The factory sensor system 108 includes a plurality of factory sensors distributed throughout the vehicle manufacturing plant 100. The factory sensor system 108 is configured to generate factory sensor data associated with the configuration of the factory assembly station 104 to the factory assembly station configuration system 102. In at least one embodiment, the factory sensor data is associated with the location of one or more factory structures 124 at the vehicle manufacturing plant 100. In at least one embodiment, the factory sensor data is associated with one or more fixed assets of the factory assembly station 104. An example of a fixed asset is a fixed device 122. In at least one embodiment, the factory sensor data is associated with the location of one or more self-moving assets 112A, 112B, 114, 116, 118, 120 of the factory assembly station 104. Examples of self-mobile assets 112A, 112B, 114, 116, 118, 120 include, but are not limited to, AMRs 112A, 112B with equipment, AMR 114 with a crane, AMR 116 with supporting parts, AMR 118 with lighting equipment, and AMR 120 with parts.

[0060] At 408, the factory assembly station configuration system 102 generates a digital twin 104DT of the factory assembly station based on the factory sensor data and the vehicle product type that complies with the operating rules. In at least one embodiment, the factory assembly station digital twin generator 206 generates a digital twin 104DT of the factory assembly station based on the factory sensor data and the vehicle product type that complies with the operating rules. Examples of operating rules include, but are not limited to, safety rules and operating permissions. At 410, the factory assembly station configuration system 102 sends the configuration of the digital twin factory assembly station 104DT to the factory operating system 106.

[0061] At 412, the factory operating system 106 implements the configuration of the factory assembly station 104 according to the configuration of the digital twin factory assembly station 104DT via instructions provided by the factory operating system 106 to the self-mobile assets 112A, 112B, 114, 116, 118, 120 of the factory assembly station 104. Upon receiving the instructions, each self-mobile asset 112A, 112B, 114, 116, 118, 120 moves to an appropriate location in the vehicle manufacturing plant 100 to 112A, 112B, 114, 116, 118, 120 to automatically configure the factory assembly station 104.

[0062] At 414, the factory assembly station configuration system 102 receives factory sensor data feedback generated by the factory sensor system 108. In at least one embodiment, the factory assembly station digital twin generator 206 receives factory sensor data feedback generated by the factory sensor system 108. The factory sensor data provides feedback regarding the configuration of the factory assembly system 104, which is generated in response to instructions provided by the factory operating system 106 to the factory assembly station 104 from the mobile assets 112A, 112B, 114, 116, 118, 120.

[0063] At 416, the factory assembly station configuration system 102 generates a digital twin 104DT of the factory assembly station based on the factory sensor data feedback. In at least one embodiment, the factory assembly station digital twin generator 206 generates the digital twin 104DT of the factory assembly station based on the factory sensor data feedback. At 418, the factory assembly station configuration system 102 determines whether the configuration of the factory assembly station 104 complies with the operating rules based on the evaluation of the digital twin 104DT of the factory assembly station. In at least one embodiment, the factory assembly station configuration evaluator 208 determines whether the configuration of the factory assembly station 104 complies with the operating rules based on the evaluation of the digital twin 104DT of the factory assembly station.

[0064] If the factory assembly station configuration system 102 determines that the configuration of the factory assembly station 104 does not comply with the operating rules, the factory assembly station configuration system 102 generates an operability status indicating that the factory assembly station 104 is not operable at 420. In at least one embodiment, if the factory assembly station configuration evaluator 208 determines that the configuration of the factory assembly station 104 does not comply with the operating rules, the factory assembly station configuration evaluator 208 generates an operability status indicating that the factory assembly station 104 is not operable at 420. The method 400 returns to 412,

[0065] If the factory assembly station configuration system 102 determines that the configuration of the factory assembly station 104 complies with the operating rules, the factory assembly station configuration system 102 generates an operability status indicating that the factory assembly station 104 is operable at 422. In at least one embodiment, if the factory assembly station configuration evaluator 208 determines that the configuration of the factory assembly station 104 complies with the operating rules, the factory assembly station configuration evaluator 208 generates an operability status indicating that the factory assembly station 104 is operable at 316. Validation of the factory assembly station 104 based on the evaluation of the digital twin 104 DT of the factory assembly station is completed, and manufacturing operations for the vehicle product type are commissioned.

[0066] refer to Figure 5, schematic diagrams showing examples 500, 502, 504 of different levels of reconfiguration of a factory assembly plant 104 that can be facilitated by a factory assembly station configuration system 102 according to at least one embodiment. The factory assembly station 104 in each example 500, 502, 504 is similar to Figure 1 . In each example 500, 502, 504, the factory assembly station 104 includes an autonomous mobile robot (AMR) 112A, 112B, 112C with equipment, an AMR 114 with a crane, an AMR 116 with supporting parts, an AMR 118 with lighting equipment, an AMR 120 with parts, fixtures 122, and a factory structure 124.

[0067] The first example 500 illustrates a low-level reconfiguration of a factory assembly station 104. The angle of an AMR 120 having a part has been modified. The position of an AMR crane 114 has been swapped with the position of an AMR 118 having a lighting device. An AMR 112B having a device has been moved. In at least one embodiment, the low-level reconfiguration of a factory assembly station 104 is accomplished via instructions provided by a human worker to self-mobile assets 112A, 112B, 114, 116, 118, 120. In at least one embodiment, the low-level reconfiguration of a factory assembly station 104 is accomplished via automatic reconfiguration of a factory assembly station 104 via instructions provided by a factory operating system 106 to self-mobile assets 112A, 112B, 114, 116, 118, 120.

[0068] The factory assembly station configuration system 102 receives factory sensor data from the factory sensor system 108. The factory sensor data provides information about the low-level reconfiguration of the factory assembly station 104. The factory assembly station configuration system 102 generates a digital twin 104DT of the reconfigured factory assembly station based on the factory sensor data. The factory assembly station configuration system 102 performs a simulation-based evaluation of the digital twin 104DT of the factory assembly station to determine whether the reconfigured factory assembly station 104 complies with the operating rules.

[0069] If the factory assembly station configuration system 102 determines that the reconfigured factory assembly station 104 complies with the operating rules based on the evaluation of the digital twin 104DT of the reconfigured factory assembly station, the factory assembly station configuration system 102 generates an operability status of the reconfigured factory assembly station 104 as operational. If the factory assembly station configuration system 102 determines that the reconfigured factory assembly station 104 does not comply with the operating rules based on the evaluation of the digital twin 104DT of the reconfigured factory assembly station, the factory assembly station configuration system 102 generates an operability status of the reconfigured factory assembly station 104 as inoperable.

[0070] If the factory assembly station configuration system 102 has determined that the operability status of the reconfigured factory assembly station 104 is inoperable, additional modifications are implemented by providing instructions to the self-moving assets 112A, 112B, 114, 116, 118, 120 of the factory assembly station 104 to attempt to make the configuration of the factory assembly station 104 comply with the operating rules, and the above process is repeated. The instructions are one of instructions provided by a human worker and instructions provided by the equipment operation station 106.

[0071] The second example 502 shows a mid-level reconfiguration of a factory assembly station 104. An AMR 120 with a part has been removed from the factory assembly station 104. An AMR 112B with a device has been removed and replaced with a different AMR 112C with a device. In at least one embodiment, the mid-level reconfiguration of the factory assembly station 104 is achieved via instructions provided by a human worker to the self-mobile assets 112A, 112B, 114, 116, 118, 120. In at least one embodiment, the mid-level reconfiguration of the factory assembly station 104 is achieved via automatic reconfiguration of the factory assembly station 104 via the factory operating system 106 providing instructions to the self-mobile assets 112A, 112B, 114, 116, 118, 120.

[0072] The factory assembly station configuration system 102 receives factory sensor data from the factory sensor system 108. The factory sensor data provides information about the mid-level reconfiguration of the factory assembly station 104. The factory assembly station configuration system 102 generates a digital twin 104DT of the reconfigured factory assembly station based on the factory sensor data. The factory assembly station configuration system 102 performs a simulation-based evaluation of the digital twin 104DT of the factory assembly station to determine whether the reconfigured factory assembly station 104 complies with the operating rules.

[0073] If the factory assembly station configuration system 102 determines that the reconfigured factory assembly station 104 complies with the operating rules based on the evaluation of the digital twin 104DT of the reconfigured factory assembly station, the factory assembly station configuration system 102 generates an operability status of the reconfigured factory assembly station 104 as operational. If the factory assembly station configuration system 102 determines that the reconfigured factory assembly station 104 does not comply with the operating rules based on the evaluation of the digital twin 104DT of the reconfigured factory assembly station, the factory assembly station configuration system 102 generates an operability status of the reconfigured factory assembly station 104 as inoperable.

[0074] If the factory assembly station configuration system 102 has determined that the operability status of the reconfigured factory assembly station 104 is inoperable, additional modifications are implemented by providing instructions to the self-moving assets 112A, 112B, 114, 116, 118, 120 of the factory assembly station 104 to attempt to make the configuration of the factory assembly station 104 comply with the operating rules, and the above process is repeated. The instructions are one of instructions provided by a human worker and instructions provided by the equipment operation station 106.

[0075] The third example 506 illustrates a high-level reconfiguration of a factory assembly station 104. The entire factory assembly station 104 has been relocated from a first location to a second location in the vehicle manufacturing plant 100. In at least one embodiment, the high-level reconfiguration of the factory assembly station 104 is achieved via instructions provided by a human worker to the self-mobile assets 112A, 112B, 114, 116, 118, 120. In at least one embodiment, the high-level reconfiguration of the factory assembly station 104 is achieved via automatic reconfiguration of the factory assembly station 104 via the factory operating system 106 providing instructions to the self-mobile assets 112A, 112B, 114, 116, 118, 120.

[0076] The factory assembly station configuration system 102 receives factory sensor data from the factory sensor system 108. The factory sensor data provides information about the relocated factory assembly station 104. The factory assembly station configuration system 102 generates a digital twin 104DT of the relocated factory assembly station based on the factory sensor data. The factory assembly station configuration system 102 performs a simulation-based evaluation on the digital twin 104DT of the relocated factory assembly station to determine whether the relocated factory assembly station 104 complies with the operating rules.

[0077] If the factory assembly station configuration system 102 determines that the relocated factory assembly station 104 complies with the operating rules based on the evaluation of the digital twin 104DT of the relocated factory assembly station, the factory assembly station configuration system 102 generates an operability status of the relocated factory assembly station 104 as operational. If the factory assembly station configuration system 102 determines that the relocated factory assembly station 104 does not comply with the operating rules based on the evaluation of the digital twin 104DT of the relocated factory assembly station, the factory assembly station configuration system 102 generates an operability status of the relocated factory assembly station 104 as inoperable.

[0078] If the factory assembly station configuration system 102 has determined that the operability status of the relocated factory assembly station 104 is inoperable, additional modifications are implemented by providing instructions to the self-moving assets 112A, 112B, 114, 116, 118, 120 of the factory assembly station 104 to attempt to make the configuration of the relocated factory assembly station 104 comply with the operating rules, and the above process is repeated. The instructions are one of instructions provided by a human worker and instructions provided by the equipment operation station 106.

[0079] In various embodiments, the factory assembly station configuration system 102 is configured to generate a digital twin of the new factory assembly station 104 according to the operating rules. The factory assembly station configuration system 102 is configured to send the digital twin of the new factory assembly station 104 to the factory operating system 106. The factory operating system 106 sends instructions to the self-mobile assets 112A, 112B, 114, 116, 118, 120 to configure the new factory assembly station 104 according to the configuration of the digital twin of the new factory assembly station 104. The use of the factory assembly station configuration system 102 in the configuration / reconfiguration of the factory assembly station 104 at the vehicle manufacturing plant 100 allows the physical manufacturing operation layout to be efficiently designed, verified and replicated within the assembly location at the vehicle manufacturing plant 100. The use of the digital twin verification at the factory assembly station configuration system 102 to implement modifications to the factory assembly station 104 will enable the factory assembly station 104 to be adjusted in real time.

[0080] The factory assembly station configuration system 102 evaluates modifications to the factory assembly station 104 via a centralized direction that prioritizes and coordinates modifications within the factory assembly station 104. Based on the vehicle type product, the digital twin (virtual replica) of the vehicle manufacturing plant 100 can be used to evaluate the entire factory floor system environment and adjust the placement of equipment and tools, materials, physical fixed structures and other assets to change or recommend a more efficient configuration. The delegation can be effectively performed by the self-mobile assets 112A, 112B, 114, 116, 118, 120 and confirmed by the evaluation of the perception infrastructure system as defined by the factory sensor system 108 and the digital twin of the vehicle manufacturing plant 100.

[0081] The factory assembly station configuration system 102 is capable of reconfiguring the manufacturing operation layout using self-mobile assets and digital twin verification. The perception infrastructure (cameras, sensors, and software) acts as a link to mirror the physical factory assembly station 104 into the digital twin 104DT of the factory assembly station. The digital twin 104DT of the factory assembly station can be used to verify the manually or automatically modified layout of the factory assembly station 104 and initiate changes to the factory assembly station 104 based on the manufacturing operation rules. The self-mobile asset can be reconfigured by changing its position or orientation in the factory assembly station 104.

[0082] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that there are a large number of variations. It should also be understood that the exemplary embodiment or multiple exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. On the contrary, the foregoing detailed description will provide a convenient roadmap for implementing the exemplary embodiment or multiple exemplary embodiments for those skilled in the art. It should be understood that various changes may be made to the functions and arrangements of the elements without departing from the scope of the present disclosure as set forth in the attached claims and their legal equivalents.

Claims

1. A factory assembly station configuration system, comprising: at least one processor; as well as at least one memory communicatively coupled to the at least one processor, the at least one memory comprising instructions that, when executed by the at least one processor, cause the at least one processor to: receiving factory sensor data generated by a factory sensor system, the factory sensor data associated with a configuration of a first factory assembly station at a vehicle manufacturing plant; generating a digital twin of the first factory assembly station based in part on the factory sensor data; determining, based on a simulation-based evaluation of the digital twin of the first factory assembly station, whether the configuration of the first factory assembly station complies with operating rules; as well as An operability status of the configuration of the first factory assembly station is generated based on the determination.

2. The system according to claim 1, wherein: The at least one memory comprises further instructions which, when executed by the at least one processor, cause the at least one processor to: receiving the plant sensor data generated by the plant sensor system, the plant sensor data being associated with a location of at least one plant structure; as well as The digital twin of the first factory assembly station is generated based in part on the location of the at least one factory structure.

3. The system according to claim 1, wherein: The at least one memory comprises further instructions which, when executed by the at least one processor, cause the at least one processor to: receiving the factory sensor data generated by the factory sensor system, the factory sensor data associated with a location of at least one fixed asset of the first factory assembly station at the vehicle manufacturing plant; as well as The digital twin of the first factory assembly station is generated based in part on the location of the at least one fixed asset of the first factory assembly station.

4. The system according to claim 1, wherein: The at least one memory includes further instructions which, when executed by the at least one processor, cause the at least one processor to: send the digital twin of the first factory assembly station to a factory operating system to enable the factory operating system to send instructions to a plurality of self-moving assets of the first factory assembly station to move to locations within the vehicle manufacturing plant based on the digital twin of the first factory assembly station, wherein each of the plurality of self-moving assets is one of: an autonomous mobile robot (AMR) with factory equipment, an AMR with parts, an AMR crane, an AMR with matching parts, and an AMR with station lighting.

5. The system according to claim 1, wherein: The at least one memory comprises further instructions which, when executed by the at least one processor, cause the at least one processor to: receiving the factory sensor data generated by the factory sensor system, the factory sensor data associated with a modification of at least one asset of the first factory assembly station; as well as The digital twin of the first factory assembly station is generated based on the modification of the at least one asset at the first factory assembly station, wherein the modification of the at least one asset comprises one of: an asset orientation change, an asset position change, swapping the position of a first asset with the position of a second asset, an asset replacement, an asset addition, and an asset removal.

6. The system according to claim 5, wherein: The modification of the at least one asset is accomplished via instructions provided by a human worker to at least one self-mobile asset of the first factory assembly station to move to a location within the vehicle manufacturing plant.

7. The system according to claim 1, wherein: The configuration of the first factory assembly station at the vehicle manufacturing plant is associated with a relocation of the first factory assembly station from a first location within the vehicle manufacturing plant to a second location within the vehicle manufacturing plant.

8. A method for configuring a factory assembly station, comprising: receiving factory sensor data generated by a factory sensor system, the factory sensor data associated with a configuration of a first factory assembly station at a vehicle manufacturing plant; generating a digital twin of the first factory assembly station based in part on the factory sensor data; determining, based on a simulation-based evaluation of the digital twin of the first factory assembly station, whether the configuration of the first factory assembly station complies with operating rules; as well as An operability status of the configuration of the first factory assembly station is generated based on the determination.

9. The method of claim 8 further includes sending the digital twin of the first factory assembly station to a factory operating system so that the factory operating system can send instructions to multiple self-mobile assets of the first factory assembly station to move to locations within the vehicle manufacturing plant based on the digital twin of the first factory assembly station.

10. The method according to claim 8, further comprising: receiving the factory sensor data generated by the factory sensor system, the factory sensor data associated with a modification of at least one asset of the first factory assembly station; as well as The digital twin of the first factory assembly station is generated based on the modification of the at least one asset at the first factory assembly station, wherein the modification of the at least one asset comprises one of: an asset orientation change, an asset position change, swapping the position of a first asset with the position of a second asset, an asset replacement, an asset addition, and an asset removal.

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