Structural panel assembly and method of manufacture

Abstract

A vehicle includes a frame defining an opening, and a structural panel assembly coupled to the opening. The structural panel assembly includes a first material, a second material opposite the first material, and a third material between the first material and the second material. The third material has an undulating shape including a peak and a valley, and the first material is coupled to the peak and the second material is coupled to the valley.

Description

[0001] TECHNICAL FIELD The present invention relates generally to structural panel assemblies and methods for making the same, and more particularly to vehicles including the structural panel assemblies and methods for making the same. Background Art

[0002] Typically, a vehicle includes a body coupled to a frame that surrounds components of the vehicle. In the example of battery-powered vehicles such as hybrid and electric vehicles, one or more portions of the body may be used to surround and / or support one or more batteries associated with the vehicle. For example, a floor panel may be used to support an occupant and surround one or more batteries associated with the vehicle. In these instances, additional support may be required to strengthen the floor panel.

[0003] Therefore, it is desirable to provide a structural panel assembly and method for manufacturing the same that reduces the need for additional supports.Furthermore, other desirable features and characteristics of the present disclosure 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] According to various embodiments, a method for manufacturing a structural panel assembly is provided. The method includes providing at least a first material, a second material, and a third material located between the first material and the second material. The method includes forming the third material to have a wavy shape, and observing the wavy shape of the third material by a sensor. The method includes controlling, by a processor, movement of a welding machine relative to the first material or the second material based on the observation to weld the first material and the second material to the third material.

[0005] Providing the first material, the second material, and the third material further includes providing a first coil of the first material, a second coil of the second material, and a third coil of the third material. Forming the third material to have a wavy shape further includes forming a plurality of peaks and a plurality of valleys in the third material using a forming roller. The first material and the second material extend along a longitudinal axis, and forming the third material to have a wavy shape further includes forming the third material to have at least one peak extending along an axis transverse to the longitudinal axis. The first material and the second material extend along a longitudinal axis, and forming the third material to have a wavy shape further includes forming the third material to have at least one peak extending along an axis parallel to the longitudinal axis. The method includes perforating the third material with at least one perforating roller prior to forming. The first material, the second material, and the third material extend along the longitudinal axis, and controlling the movement of the welding machine by the processor further includes: determining the speed of the welding machine by the processor; determining the position of the wavy shape relative to an axis transverse to the longitudinal axis based on observation; determining the position of the welding machine relative to the axis based on position data associated with the welding machine by the processor; calculating an error value by the processor based on the difference between the position of the wavy shape and the position of the welding machine; adjusting the speed of the welding machine based on the error value by the processor; and outputting one or more control signals by the processor to the actuator to move the welding machine at the speed. Determining the speed of the welding machine further includes: calculating the pitch angle of the welding path of the welding machine by the processor; and calculating the speed by the processor based on the pitch angle and the speed associated with the supply of the first material, the second material, and the third material. Calculating the pitch angle is based on the spacing of the wavy shape, the width of the first material, and the number of welding machines. Adjusting the speed of the welding machine further includes: applying a proportional, integral, and differential algorithm by the processor to determine a correction term for the speed of the welding machine; adding the correction term to the speed of the welding machine by the processor to obtain a new speed; and outputting one or more control signals by the processor to the actuator to move the welding machine at the new speed. Welding the first material and the second material to the third material further includes: forming a plurality of intermittent welds between the first material and the third material using a welding machine; and forming a second plurality of intermittent welds between the second material and the third material using a welding machine.

[0006] According to various embodiments, a method for manufacturing a structural panel assembly is also provided. The method includes providing a first coil of at least a first material, a second coil of a second material, and a third coil of a third material, the third material being supplied by the third coil so that the third material is located between the first material and the second material, and the third material is formed into a wavy shape including peaks and valleys. The method includes observing at least one of the peaks and valleys of the third material by a sensor, and controlling the movement of a first welding machine relative to the first material based on the observation of the peaks by a processor to weld the first material to the peaks of the third material. The method includes controlling the movement of a second welding machine relative to the first material based on the observation of the valleys by a processor to weld the second material to the valleys of the third material.

[0007] Forming the third material to have a wavy shape further includes forming a plurality of peaks and a plurality of valleys in the third material using a pair of forming rollers. The first material and the second material extend along the longitudinal axis, and forming the third material to have a wavy shape further includes forming the third material to have peaks and valleys each extending along an axis transverse to the longitudinal axis. The first material and the second material extend along the longitudinal axis, and forming the third material to have a wavy shape further includes forming the third material to have peaks and valleys each extending along an axis parallel to the longitudinal axis. The method includes perforating the third material with a pair of perforating rollers before forming. The first material, the second material, and the third material extend along the longitudinal axis, and controlling the movement of the first welding machine by the processor further includes: determining the speed of the first welding machine by the processor; determining the position of the peak relative to the axis transverse to the longitudinal axis based on observation; determining the position of the first welding machine relative to the axis based on the position data associated with the first welding machine by the processor; calculating an error value by the processor based on the difference between the position of the peak and the position of the first welding machine; adjusting the speed of the first welding machine by the processor based on the error value; and outputting one or more control signals to the actuator by the processor to move the first welding machine at the speed to weld the first material to the peak of the third material. Determining the speed of the first welder further includes: calculating, by the processor, a pitch angle of a welding path of the first welder; and calculating, by the processor, the speed based on the pitch angle and a speed associated with at least the supply of the third material. The wavy shape includes a plurality of peaks, and calculating the pitch angle is based on the spacing between adjacent peaks, the width of the first material, and the number of first welders. Adjusting the speed of the first welder further includes: applying, by the processor, a proportional, integral, and derivative algorithm to determine a correction term for the speed of the first welder; adding, by the processor, the correction term to the speed of the first welder to obtain a new speed; and outputting, by the processor, one or more control signals to an actuator to move the first welder at the new speed.

[0008] According to various embodiments, a vehicle is also provided. The vehicle includes a frame defining an opening, and a structural panel assembly is coupled to the opening. The structural panel assembly includes a first material, a second material opposite the first material, and a third material located between the first material and the second material. The third material has a wavy shape including peaks and valleys, and the first material is coupled to the peaks and the second material is coupled to the valleys.

[0009] The first material, the second material, and the third material are composed of metals or metal alloys. The first material is welded to the peaks, and the second material is welded to the valleys. The first material is welded to the peaks via a plurality of intermittent welds, and the second material is welded to the valleys via a second plurality of intermittent welds. The structural panel assembly has a longitudinal axis, and the peaks and valleys each extend along an axis parallel to the longitudinal axis. The structural panel assembly has a longitudinal axis, and the peaks and valleys each extend along an axis perpendicular to the longitudinal axis. The third material includes a plurality of openings. The plurality of openings are defined along a wall interconnecting the peaks and valleys. The openings separate a passenger compartment from a storage compartment for one or more batteries associated with the vehicle.

[0010] According to various embodiments, a vehicle is also provided. The vehicle includes a frame that defines an opening that separates a passenger compartment from a storage compartment. The vehicle includes a structural panel assembly coupled to the opening to surround the opening. The structural panel assembly includes a first material, a second material opposite to the first material, and a third material located between the first material and the second material. The third material has a wavy shape including peaks and valleys. The first material, the second material, and the third material are composed of metals or metal alloys, and the first material is welded to the peaks, and the second material is welded to the valleys.

[0011] The first material is welded to the peaks via a plurality of intermittent welds, and the second material is welded to the valleys via a second plurality of intermittent welds. The structural panel assembly has a longitudinal axis, and the peaks and valleys each extend along an axis parallel to the longitudinal axis. The structural panel assembly has a longitudinal axis, and the peaks and valleys each extend along an axis perpendicular to the longitudinal axis. The third material includes a plurality of openings. The plurality of openings are defined along a wall interconnecting the peaks and valleys.

[0012] According to various embodiments, a system for manufacturing a structural panel assembly for a vehicle is also provided. The system includes a first material, a second material, and a third material located between the first material and the second material. The system includes a pair of forming rollers, the forming rollers are configured to receive the third material to give the third material a wavy shape including peaks and valleys; and a sensor that observes at least one of the peaks and valleys. The system includes a controller having a processor, the processor being configured to: output one or more control signals based on the observation of the peaks to control the movement of the welding machine relative to the first material to weld the first material to the third material at the peaks.

[0013] The structural panel assembly extends along a longitudinal axis, and the peak and the valley each extend along an axis transverse to the longitudinal axis. The structural panel assembly extends along the longitudinal axis, and the peak and the valley each extend along an axis parallel to the longitudinal axis. The system includes at least one perforated roller configured to form a plurality of openings in the third material. The controller is further configured to: determine a speed of a welding machine, determine a location of the peak based on observation of the peak, determine a location of the welding machine based on location data associated with the welding machine, calculate an error value based on a difference between the location of the peak and the location of the welding machine, and adjust the speed of the welding machine based on the error value. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Exemplary embodiments will be described below with reference to the following drawings, wherein like numerals represent like elements, and wherein:

[0015] Figure 1 is a bottom perspective view of a vehicle including an exemplary structural panel assembly according to various embodiments;

[0016] Figure 1A According to various embodiments Figure 1 a simplified side view of a vehicle including a structural panel assembly coupled to a frame of the vehicle;

[0017] Figure 1B According to various embodiments Figure 1 a simplified top perspective view of a vehicle including a structural panel assembly coupled to a frame of the vehicle;

[0018] Figure 2 yes Figure 1 an end view of a structural panel assembly;

[0019] Figure 3 is a perspective view of another exemplary structural panel assembly for use with a vehicle;

[0020] Figure 4 yes Figure 3 a perspective view of a structural panel assembly of FIG. 1 , wherein a first top panel is shown in phantom to illustrate the structure below;

[0021] Figure 5 is a perspective view of another exemplary structural panel assembly for use with a vehicle;

[0022] Figure 6 It is used to form Figure 1-Figure 5 A schematic diagram of a manufacturing system for a structural panel assembly;

[0023] Figure 7 is with Figure 6 manufacturing systems to form Figure 5 a schematic diagram of at least one forming roller of a structural panel assembly;

[0024] Figure 8 yes Figure 6 A schematic top view of a portion of a manufacturing system;

[0025] Fig. 9 is a data flow diagram illustrating control modules associated with a manufacturing control system of a manufacturing system according to various embodiments; and

[0026] Figure 10-12 is a flow chart illustrating a control method performed by a manufacturing control system according to various embodiments. DETAILED DESCRIPTION

[0027] The following detailed description is merely exemplary in nature and is not intended to limit application and use. In addition, there is no intention to be bound by any express or implied theory presented in the foregoing introduction, the invention content or the detailed description below. As used herein, the term module refers to any hardware, software, firmware, electronic control component, processing logic and / or processor device, alone or in any combination, including but not limited to: application-specific integrated circuits (ASICs), electronic circuits, processors (shared, dedicated or groups) and memories that execute one or more software or firmware programs, combinational logic circuits and / or other suitable components that provide the described functions.

[0028] 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.

[0029] For the sake of brevity, conventional techniques related to other functional aspects of signal processing, data transmission, signaling, control, machine learning models, and systems (and the various operating components of the systems) may not be described in detail herein. In addition, the connecting lines shown in the various figures included herein are intended to represent example functional relationships and / or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in the embodiments of the present disclosure.

[0030] As used herein, the term "axial" refers to a direction that is generally parallel to or coincident with the axis of rotation, axis of symmetry, or centerline of one or more components. For example, in a cylinder or disk having a centerline and generally circular ends or opposing faces, the "axial" direction may refer to a direction that extends generally parallel to the centerline between the opposing ends or opposing faces. In some instances, the term "axial" may be used for components that are not cylindrical (or otherwise radially symmetrical). For example, the "axial" direction of a rectangular housing containing a rotating axis may be considered to be a direction that is generally parallel to or coincident with the axis of rotation of the axis. In addition, the term "radial" as used herein may refer to the direction or relationship of a component relative to a line extending outward from a shared centerline, axis, or similar reference, for example in a plane perpendicular to the centerline or axis of a cylinder or disk. In some instances, components may be considered to be "radially" aligned even if one or two of the components may not be cylindrical (or otherwise radially symmetrical). In addition, the terms "axial" and "radial" (and any derivatives) may include directional relationships that are not precisely aligned with (e.g., oblique to) the true axial and radial dimensions, provided that the relationship is primarily in the corresponding nominal axial or radial direction. As used herein, the term "approximately" means within 10% to account for manufacturing tolerances. In addition, the term "substantially" means within 10% to account for manufacturing tolerances.

[0031] refer to Figure 1 , a structural panel assembly 100 is shown associated with a frame 12 of a vehicle 10. The vehicle 10 is described below as a hybrid or electric vehicle including one or more batteries, however, it should be understood that the structural panel assembly 100 can be used with other vehicles, as well as in other non-vehicle applications. In addition, while the vehicle 10 may include a passenger car, it should be understood that any other vehicle, including motorcycles, trucks, sport utility vehicles (SUVs), recreational vehicles (RVs), marine vessels, aircraft, can include one or more structural panel assemblies 100. In one example, additional reference Figure 1A and Figure 1B, the structural panel assembly 100 is a floor that separates a passenger compartment (generally indicated at 14) from a battery storage compartment (generally indicated at 16). In this example, the frame 12 includes a pair of opposed longitudinal rails 18 extending along axes substantially parallel to the longitudinal axis L of the vehicle 10, and a pair of crossbars 20 coupled to each of the longitudinal rails 18 to define a substantially rectangular floor area. The structural panel assembly 100 is coupled to a first surface 22 of each of the longitudinal rails 18 and crossbars 20 to define a floor of the passenger compartment 14 of the vehicle 10 and surround the ends of the battery storage compartment 16. In one example, the structural panel assembly 100 is welded to the first surface 22 of each of the longitudinal rails 18 and crossbars 20. The structural panel assembly 100 provides support for occupants of the passenger compartment 14 while also providing impact resistance to protect one or more batteries contained within the battery storage compartment 16.

[0032] refer to Figure 2 , showing the structural panel assembly 100 in more detail. In one example, the structural panel assembly 100 includes a first top panel 102, a second bottom panel 104, and a third middle panel 106. In this example, each of the top panel 102, the bottom panel 104, and the middle panel 106 is composed of a metal or metal alloy material or material 402a, 404a, 406a, respectively, including but not limited to aluminum, aluminum alloy, steel, etc. The top panel 102 and the bottom panel 104 have substantially the same thickness T. The thickness T is about 0.7 millimeters (mm) to about 1.1 millimeters (mm), and in one example, about 0.9 millimeters (mm). For example, the middle panel 106 can have a thickness T1 that is different from and less than the thickness T to provide weight savings. The thickness T is about 0.3 millimeters (mm) to about 0.7 millimeters (mm), and in one example, about 0.5 millimeters (mm). In other examples, the thicknesses T, T1 of the top panel 102, the bottom panel 104, and the middle panel 106 can be substantially the same. The thickness T, T1 is substantially uniform on each of the top panel 102, the bottom panel 104, and the middle panel 106. The top panel 102 and the bottom panel 104 are each planar or flat, and each has a thickness T, T2, T3, T4, T5, T6, T7, T8, T9, T10, T11, T12, and T13. Figure 6 ). Axis A1 is substantially parallel to axis A2 and extends in Figure 1 In the example of FIG. 1 , the axes A1 and A2 are substantially perpendicular to the longitudinal axis L. The top panel 102 and the bottom panel 104 are also oriented along the longitudinal axis L in the X direction ( Figure 6 ) extends on the vehicle 10. Generally, in the example of the vehicle 10, each of the top panel 102 and the bottom panel 104 can be trimmed or cut along an axis parallel to the axes A1, A2 to define a longitudinal axis L or X direction ( Figure 6) of a predefined length L1 of about 1.5 meters (m) to about 2.5 meters (m). It should be noted that the structural panel assembly 100 can be cut into different lengths based on the size of the vehicle 10. The structural panel assembly 100 also has a predefined width W, which is about 1.3 meters (m) to about 2.0 meters (m) in this example. The structural panel assembly 100 has a predefined panel thickness PT, which is about 20 millimeters (mm) to about 50 millimeters (mm) in this example.

[0033] In one example, the panel thickness PT is defined by the middle panel 106. In this example, the middle panel 106 has a wavy shape 110 defined over the length L1 of the structural panel assembly 100. In one example, the wavy shape 110 includes a plurality of peaks 112 alternating with a plurality of valleys 114. The peaks 112 are spaced apart from each other by a peak distance PD, which in one example is about 40 millimeters (mm) to about 100 millimeters (mm). A plurality of walls 116 interconnect the peaks 112 and valleys 114. In this example, each of the walls 116 extends at an angle α of about 45 degrees relative to the top panel 102. In addition, each of the walls 116 extends at an angle α of about 45 degrees relative to the bottom panel 104. In this example, each of the walls 116 is solid or has no openings. Typically, when the middle panel 106 is coupled to the top panel 102 and the bottom panel 104, each of the walls 116 is defined to extend at an angle of approximately 45 degrees between the top panel 102 and the bottom panel 104 to define a plurality of closed sections or triangles 118 in cross-section. The triangles 118 defined by the wavy shape 110 act as trusses and distribute radial and / or axial loads received across the surface of the structural panel assembly 100. The formation of the closed sections or triangles 118 also aids in energy absorption and resists buckling and bending of the structural panel assembly 100. The load distribution resulting from the wavy shape 110 of the middle panel 106 protects the battery storage chamber 16 ( Figure 1 ) and also enables the structural panel assembly 100 to withstand the passenger compartment 14 ( Figure 1 ) The weight of the occupants.

[0034] In one example, the peaks 112 are coupled to the top panel 102 and the valleys 114 are coupled to the bottom panel 104 such that a triangle 118 is formed extending along the axes A1, A2. In this example, the peaks 112 and valleys 114 are each coupled to a respective one of the top panel 102 and the bottom panel 104 via a series of welds to form the closed portion or triangle 118. Typically, the top panel 102 and the bottom panel 104 are each welded to the middle panel 106 via a seam weld or a plurality of line welds 120 that are welded in the X direction ( Figure 6) intermittent or spaced apart. It should be noted that in other examples, the top panel 102 and the bottom panel 104 can each be welded to the middle panel 106 via a spot weld or multiple spot welds, which are intermittent or spaced apart in the X direction. In addition, it should be noted that the stitch welds or line welds 120, although shown as linear welds in this article, can also be formed with an oscillating pattern, such as a sinusoidal pattern, if desired. The line welds 120 are defined as extending along the top panel 102 in the direction of the axis A1 at each of the peaks 112 to weld the peaks 112 to the top panel 102. The line welds 120 are defined as extending along the bottom panel 104 in the direction of the axis A1 at each of the valleys 114 to weld the valleys 114 to the bottom panel 104. The line welds 120 rigidly and fixedly couple the top panel 102 and the bottom panel 104 to the middle panel 106. Typically, the line welds 120 are spaced apart in the direction of the axis A1 such that the line welds 120 are discrete or discontinuous along a respective one of the peaks 112 and the valleys 114. By providing intermittent or spaced apart line welds 120, a problem in one of the line welds 120 does not necessarily propagate to another of the line welds 120. In other words, in instances where a problem occurs with a line weld 120, the end of each individual "stitch" or line weld 120 serves as a stopping point. In this example, each of the peaks 112 and each of the valleys 114 includes at least one or more line welds 120. It should be noted that in other embodiments, one or more of the peaks 112 and / or valleys 114 may be free of a line weld 120, and other types of welds may be used to couple the top panel 102 and the bottom panel 104 to the middle panel 106.

[0035] It should be noted that in other embodiments, the structural panel assembly 100 may be configured differently to provide support and impact resistance. Figure 3 , showing a structural panel assembly 200. Since the structural panel assembly 200 includes Figure 1-Figure 2 The components of the structural panel assembly 100 discussed above are identical or similar components, and therefore the same reference numerals will be used to represent identical or similar components. In one example, the structural panel assembly 200 is shown in greater detail. The structural panel assembly 200 can be coupled to the first surface 22 of each of the longitudinal rails 18 and the crossbars 20 to define a floor of the passenger compartment 14 of the vehicle 10 and to enclose the battery storage compartment 16 ( Figure 1 The structural panel assembly 200 provides support for occupants of the passenger compartment 14 while also providing impact resistance to protect one or more batteries contained within the battery storage compartment 16.

[0036] In one example, the structural panel assembly 200 includes a first top panel 102, a second bottom panel 104, and a third intermediate panel 206. In this example, the intermediate panel 206 is composed of material 406a. The intermediate panel 206 has a thickness T1, and the thickness T1 is substantially uniform across the intermediate panel 206. The top panel 102 and the bottom panel 104 are each planar or flat, and each extends along a respective axis A1, A2. The axis A1 is substantially parallel to the axis A2, and is substantially parallel to the axis A2. Figure 3 In the example of FIG. 1 , the axes A1, A2 are substantially perpendicular to the longitudinal axis L2 of the structural panel assembly 200. Generally, each of the top panel 102, the bottom panel 104, and the intermediate panel 206 can be trimmed or cut along an axis parallel to the axes A1, A2 to define a structural panel assembly 200 having a predefined length L1. The structural panel assembly 200 also has a predefined width W. The structural panel assembly 200 has a predefined panel thickness PT.

[0037] In one example, the panel thickness PT is defined by the middle panel 206. In this example, the middle panel 206 has a wavy shape 210 defined over the length L1 of the structural panel assembly 200. In one example, the wavy shape 210 includes a plurality of peaks 212 alternating with a plurality of valleys 214. The peaks 212 are spaced apart from each other by a peak distance PD. A plurality of walls 216 interconnect the peaks 212 and the valleys 214. In this example, each of the walls 216 extends at an angle α of approximately 45 degrees relative to the top panel 102. In addition, each of the walls 216 extends at an angle α of approximately 45 degrees relative to the bottom panel 104. Generally, when the middle panel 206 is coupled to the top panel 102 and the bottom panel 104, each of the walls 216 is defined to extend at an angle of approximately 45 degrees between the top panel 102 and the bottom panel 104 to define a plurality of closed portions or triangles 218 in cross section. The triangles 218 defined by the wavy shape 210 act as trusses and distribute radially and / or axially received loads across the surface of the structural panel assembly 200. The formation of the closed portions or triangles 218 also assists in energy absorption and resists buckling and bending of the structural panel assembly 200. The load distribution resulting from the wavy shape 210 of the intermediate panel 206 protects the battery storage chamber 16 ( Figure 1 ) and also enables the structural panel assembly 200 to withstand the passenger compartment 14 ( Figure 1 ) The weight of the occupants.

[0038] refer to Figure 4In one example, each of the walls 216 includes at least one or more openings 220, the openings being defined as extending through the wall 216 from a first surface 216a of the wall 216 to an opposing second surface 216b of the wall 216. In this example, the plurality of openings 220 include a plurality of alternating isosceles triangles, the isosceles triangles being defined as extending along axes parallel to the axes A1, A2. In other words, the plurality of openings 220 are defined such that a vertex 222 of a first one of the openings 220 is adjacent to a base 224 of a second one of the adjacent openings 220. Generally, the openings 220 are defined such that the wall 216 has a plurality of legs 226 interconnecting respective peaks 212 with respective valleys 214. The plurality of legs 226 are defined to extend at an angle of approximately 45 degrees relative to respective valleys 214. The openings 220 provide mass savings for the structural panel assembly 200. It should be noted that although openings 220 are shown and described herein as comprising a plurality of alternating isosceles triangles, openings 220 may have any desired shape and may be formed in any predetermined pattern.

[0039] The peaks 212 are coupled to the top panel 102 and the valleys 214 are coupled to the bottom panel 104 such that a triangle 218 is formed extending along the axes A1, A2. In this example, the peaks 212 and valleys 214 are each coupled to a respective one of the top panel 102 and the bottom panel 104 via a series of welds. Typically, the top panel 102 and the bottom panel 104 are each welded to the middle panel 206 via a seam weld or a plurality of line welds 120 that are welded in the Y direction ( Figure 6) are intermittent or spaced apart on the X direction. It should be noted that in other examples, the top panel 102 and the bottom panel 104 can each be welded to the middle panel 206 via a spot weld or multiple spot welds, which are intermittent or spaced apart in the X direction. In addition, it should be noted that the stitch welds or line welds 120, although shown as linear welds in this document, can also be formed with an oscillating pattern, such as a sinusoidal pattern, if desired. The line welds 120 are defined as extending along the top panel 102 in the direction of the axis A1 at each of the peaks 212 to weld the peaks 212 to the top panel 102. The line welds 120 are defined as extending along the bottom panel 104 in the direction of the axis A1 at each of the valleys 214 to weld the valleys 214 to the bottom panel 104. The line welds 120 rigidly and fixedly couple the top panel 102 and the bottom panel 104 to the middle panel 206. Typically, the line welds 120 are spaced apart in the direction of the axis A1 such that the line welds 120 are discrete or discontinuous along a respective one of the peaks 212 and the valleys 214. In this example, each of the peaks 212 and each of the valleys 214 include at least one or more line welds 120. It should be noted that in other embodiments, one or more of the peaks 212 and / or valleys 214 may be free of line welds 120, and other types of welds may be used to couple the top panel 102 and the bottom panel 104 to the middle panel 206.

[0040] It should be noted that in other embodiments, the structural panel assembly 100 may be configured differently to provide support and impact resistance. Figure 5 , showing a structural panel assembly 300. Since the structural panel assembly 300 includes Figure 1-Figure 2 The components of the structural panel assembly 100 discussed above are identical or similar components, and therefore the same reference numerals will be used to represent identical or similar components. In one example, the structural panel assembly 300 is shown in greater detail. The structural panel assembly 300 can be coupled to the first surface 22 of each of the longitudinal rails 18 and the crossbars 20 to define a floor of the passenger compartment 14 of the vehicle 10 and to enclose the battery storage compartment 16 ( Figure 1 The structural panel assembly 300 provides support for occupants of the passenger compartment 14 while also providing impact resistance to protect one or more batteries contained within the battery storage compartment 16 .

[0041] In one example, the structural panel assembly 300 includes a first top panel 102, a second bottom panel 104, and a third intermediate panel 306. In this example, the intermediate panel 306 is composed of material 406a. The intermediate panel 306 has a thickness T1, and the thickness T1 is substantially uniform across the intermediate panel 306. The top panel 102 and the bottom panel 104 are each planar or flat, and each extends along a respective axis A1, A2. The axis A1 is substantially parallel to the axis A2, and is substantially parallel to the axis A2. Figure 5 In the example of FIG. 3 , the axes A1, A2 are substantially perpendicular to the longitudinal axis L3 of the structural panel assembly 300. Generally, each of the top panel 102, the bottom panel 104, and the intermediate panel 306 can be trimmed or cut along an axis parallel to the axes A1, A2 to define a structural panel assembly 300 having a predefined length L1. The structural panel assembly 300 also has a predefined width W. The structural panel assembly 300 has a predefined panel thickness PT.

[0042] In one example, the panel thickness PT is defined by the middle panel 306. In this example, the middle panel 306 has a wavy shape 310 defined over the length L1 of the structural panel assembly 300. In one example, the wavy shape 310 includes a plurality of peaks 312 alternating with a plurality of valleys 314. The peaks 312 are spaced apart from each other by a peak distance PD. A plurality of walls 316 interconnect the peaks 312 and the valleys 314. In this example, each of the walls 316 extends at an angle α relative to the top panel 102. In addition, each of the walls 316 extends at an angle α relative to the bottom panel 104. In this example, each of the walls 316 is solid. Typically, when the middle panel 306 is coupled to the top panel 102 and the bottom panel 104, each of the walls 316 is defined to extend at an angle of approximately 45 degrees between the top panel 102 and the bottom panel 104 to define a plurality of closed portions or triangles 318 in cross section. The triangles 318 defined by the wavy shape 310 act as trusses and distribute radially or axially received loads across the surface of the structural panel assembly 300. The formation of the closed portions or triangles 318 also assists in energy absorption and resists buckling and bending of the structural panel assembly 300. The load distribution resulting from the wavy shape 310 of the intermediate panel 106 protects the battery storage chamber 16 ( Figure 1 ) and also enables the structural panel assembly 300 to withstand the passenger compartment 14 ( Figure 1 ) The weight of the occupants.

[0043] In one example, the peaks 312 are coupled to the top panel 102 and the valleys 314 are coupled to the bottom panel 104 such that a triangle 318 is formed extending along the longitudinal axis L3. In this example, the peaks 312 and valleys 314 are each coupled to a respective one of the top panel 102 and the bottom panel 104 via a series of welds. Typically, the top panel 102 and the bottom panel 104 are each welded to the middle panel 306 via a seam weld or a plurality of line welds 320 that are welded in the X direction ( Figure 6 ) are intermittent or spaced apart on the X direction. It should be noted that in other examples, the top panel 102 and the bottom panel 104 can each be welded to the middle panel 306 via a spot weld or multiple spot welds, which are intermittent or spaced apart in the X direction. In addition, it should be noted that the stitch welds or line welds 320, although shown as linear welds herein, can also be formed with an oscillating pattern, such as a sinusoidal pattern, if desired. The line welds 320 are defined as extending along the top panel 102 in the direction of the longitudinal axis L3 at each of the peaks 312 to weld the peaks 312 to the top panel 102. The line welds 320 are defined as extending along the bottom panel 104 in the direction of the longitudinal axis L3 at each of the valleys 314 to weld the valleys 314 to the bottom panel 104. The line welds 320 rigidly and fixedly couple the top panel 102 and the bottom panel 104 to the middle panel 306. Typically, the line welds 320 are spaced apart in the direction of the longitudinal axis L3 such that the line welds 320 are discrete or discontinuous along a respective one of the peaks 312 and valleys 314. By providing intermittent or spaced apart line welds 320, a problem in one of the line welds 320 does not necessarily propagate to another of the line welds 320. In other words, in instances where a problem occurs with a line weld 320, the end of each individual "stitch" or line weld 320 serves as a stopping point. In this example, each of the peaks 312 and each of the valleys 314 include at least one or more line welds 320. It should be noted that in other embodiments, one or more of the peaks 312 and / or valleys 314 may be free of a line weld 320, and other types of welds may be used to couple the top panel 102 and the bottom panel 104 to the middle panel 306.

[0044] In one example, reference Figure 6, a manufacturing system 400 for forming or manufacturing a structural panel assembly 100, 200, 300 is shown. In this example, the manufacturing system 400 includes a first top material coil 402, a second bottom material coil 404, a third intermediate material coil 406, at least one forming roller 408, 508, at least one orientation roller 410, at least one thickness setting system 412, a welding system 414, a sensor system 416, and a controller 418. The manufacturing system 400 may also include a cutting system 420. In the example of the structural panel assembly 200, the manufacturing system 400 also includes at least one perforating roller 422. The top material coil 402, the bottom material coil 404, the intermediate material coil 406, the at least one thickness setting system 412, the welding system 414, the sensor system 416, and the cutting system 420 may communicate with the controller 418 via a suitable communication architecture that supports the transmission of power, data, etc., including but not limited to a communication bus. It should be noted that in some embodiments, the manufacturing system 400 may also include a press or at least a pair of press rollers that communicate with the top material coil 402 and / or the bottom material coil 404 to receive the corresponding materials 402a, 404a. The press or at least a pair of press rollers may be used to add holes or other perforated features to enable subsequent assembly of the materials 402a, 404a to the frame 12 ( Figure 1 ). The press or at least a pair of press rollers may also communicate with the controller 418 via a suitable communication architecture supporting transmission of power, data, etc., including but not limited to a communication bus.

[0045] The top material coil 402 includes a material 402a for forming the top panel 102. In this example, the top material coil 402 includes a material 402a formed into a flat or planar continuous sheet and wound into a coil to form a cylinder. The top material coil 402 may include a first central hole 424 receiving an axis 426 or the like to enable the top material coil 402 to rotate. For example, the top material coil 402 may be coupled to the axis 426 and driven by a motor in communication with the controller 418, and rotated at a predetermined speed in response to one or more control signals from the controller 418 to feed the material 402a for the top panel 102 to at least one directional roller 410. The top material coil 402 may also be supported by a frame or the like coupled to the axis 434 to support the top material coil 402 during rotation. In one example, the width of the top material coil 402 in the Y direction is at least equal to the width W of the structural panel assembly 100, 200, 300. In the coordinate system 435, the Y direction is perpendicular to the X direction and the Z direction. The X direction is parallel to the direction of travel D of the materials 402a, 404a, 406a through the manufacturing system 400, and the Z direction is perpendicular to the direction of travel D and the X direction.

[0046] The bottom material coil 404 includes a material 404a for forming the bottom panel 104. In this example, the bottom material coil 404 includes a material 404a formed into a flat or planar continuous sheet and wound into a coil to form a cylinder. The bottom material coil 404 may include a second central hole 428 for receiving an axis 430 or the like so that the bottom material coil 404 can rotate. For example, the bottom material coil 404 may be coupled to the axis 430 and driven by a motor in communication with the controller 418, and rotated at a predetermined speed in response to one or more control signals from the controller 418 to feed the material 404a for the bottom panel 104 to at least one directional roller 410. The bottom material coil 404 may also be supported by a frame or the like coupled to the axis 434 to support the bottom material coil 404 during rotation. In one example, the width of the bottom material coil 404 in the Y direction is at least equal to the width W of the structural panel assembly 100, 200, 300.

[0047] The intermediate material coil 406 includes a material 406a for forming the intermediate panel 106. In this example, the intermediate material coil 406 includes a material 406a formed into a flat or planar continuous sheet and wound into a coil to form a cylinder. The intermediate material coil 406 may include a third central hole 432 that receives a shaft 434 or the like so that the intermediate material coil 406 can rotate. For example, the intermediate material coil 406 may be coupled to the shaft 434 and driven by a motor that communicates with the controller 418, and rotate at a predetermined speed in response to one or more control signals from the controller 418 to feed the material 406a for the intermediate panel 106 to at least one forming roller 408. The intermediate material coil 406 may also be supported by a frame or the like coupled to the shaft 434 to support the intermediate material coil 406 during rotation. In one example, the width of the intermediate material coil 406 in the Y direction is at least equal to the width W of the structural panel assembly 100, 200, 300.

[0048] In one example, at least one forming roller 408 includes a first forming roller 408a and a second forming roller 408b. The first forming roller 408a is opposite to the second forming roller 408b and is located upstream of the second forming roller 408b in the direction of travel of the material 406a for the intermediate panel 106, 206. In this example, the first forming roller 408a is offset from the second forming roller 408b. The forming rollers 408a, 408b include a corresponding plurality of gear teeth 436a, 436b. The gear teeth 436a of the first forming roller 408a are formed to intermesh with the gear teeth 436b of the second forming roller 408b. In this example, the top platform TL associated with each of the gear teeth 436a, 436b extends along an axis transverse to the direction of the material 406a of the intermediate material coil 406, so that the wavy shape 110, 210 includes a substantially perpendicular direction to the structural panel assembly 100, 200 ( Figure 1 and Figure 3 ) of the longitudinal axis L of the intermediate panel 106, 206. The forming rollers 408a, 408b may each include a roller center hole 438 that receives an axle 440 or the like to enable each of the forming rollers 408a, 408b to rotate. As the material 406a of the intermediate material coil 406 passes through the forming rollers 408a, 408b, the forming rollers 408a, 408b rotate and the gear teeth 436a, 436b cooperate to form the wavy shape 110, 210 in the material 406a of the intermediate panel 106, 206. Typically, the gear teeth 436a, 436b are defined around the circumference of the respective forming rollers 408a, 408b with a pitch that defines the peaks 112, 212 and the valleys 114, 214 at an angle α. The forming rollers 408a, 408b may also be supported by a frame or the like coupled to the respective shafts 440 to support the forming rollers 408a, 408b during rotation. In one example, the width of the forming rollers 408a, 408b in the Y direction is at least equal to the width W of the structural panel assembly 100, 200.

[0049] It should be noted that in the example of the intermediate panel 306, the forming rollers 408a, 408b may be configured differently. Figure 7, at least one forming roller 508 is shown. The at least one forming roller 508 includes a first forming roller 508a and a second forming roller 508b. The first forming roller 508a is opposite to the second forming roller 508b and is located upstream of the second forming roller 508b in the direction of travel of the material 406a for the intermediate panel 306. In this example, the first forming roller 508a is offset from the second forming roller 508b. The forming rollers 508a, 508b include a corresponding plurality of gear teeth 536a, 536b. The gear teeth 536a of the first forming roller 508a are formed to mesh with the gear teeth 536b of the second forming roller 508b. In this example, the top platform TL1 associated with each of the gear teeth 536a, 536b extends along an axis parallel to the direction of the material 406a of the intermediate material coil 406, so that the wavy shape 310 includes a substantially parallel to the structural panel assembly 300 ( Figure 5 ) of the longitudinal axis L3 of the intermediate panel 306. The forming rollers 508a, 508b may each include a roller center hole 538 that receives an axle 540 or the like to enable each of the forming rollers 508a, 508b to rotate. When the material 406a of the intermediate material coil 406 passes through the forming rollers 508a, 508b, the forming rollers 508a, 508b rotate, and the gear teeth 536a, 536b cooperate to form the wavy shape 310 in the material 406a of the intermediate panel 306. Typically, the gear teeth 536a, 536b are defined around the circumference of the respective forming rollers 508a, 508b, with a pitch that defines the peaks 312 and the valleys 314 at an angle α. The forming rollers 508a, 508b may also be supported by a frame or the like that is coupled to the respective axle 540 to support the forming rollers 508a, 508b during rotation. In one example, the width of the forming rollers 508a, 508b in the Y direction is at least equal to the width W of the structural panel assembly 300.

[0050] Refer to Figure 6, at least one orientation roller 410 includes a first orientation roller 410a and a second orientation roller 410b. The first orientation roller 410a is opposite to the second orientation roller 410b and is spaced apart from the first orientation roller 410a to enable the wavy shapes 110, 210, 310 in the material 402a of the top panel 102, the material 404a of the bottom panel 104, and the material 406a of the intermediate panels 106, 206, 306. Generally, the orientation rollers 410a, 410b ensure that the material 402a of the top panel 102 and the material 404a of the bottom panel 104 are axially aligned with the peaks 112, 212, 312 and valleys 114, 214, 314 of the intermediate panels 106, 206, 306, respectively. The orientation rollers 410a, 410b also ensure that the material 402a of the top panel 102 and the material 404a of the bottom panel 104 are substantially planar and smooth before reaching the welding system 414. In other words, the orientation rollers 410a, 410b may remove the curvature imparted by the material 402a of the top panel 102 and the material 404a of the bottom panel 104, respectively, being wound into coils.

[0051] The orientation rollers 410a, 410b can each include a second roller center hole 442 that receives an axle 444 or the like to enable each of the orientation rollers 410a, 410b to rotate. The orientation rollers 410a, 410b have substantially smooth outer circumferences, which help to align the material 402a of the top panel 102 and the material 404a of the bottom panel 104, respectively, while ensuring that the material 402a of the top panel 102 and the material 404a of the bottom panel 104 are substantially planar before reaching the welding system 414. As the material 402a of the top panel 102 and the material 404a of the bottom panel 104 pass through the orientation rollers 410a, 410b, the orientation rollers 410a, 410b rotate and the outer circumferences of the orientation rollers 410a, 410b cooperate to axially align the material 402a of the top panel 102 and the material 404a of the bottom panel 104 with the wavy shapes 110, 210, 310 in the material 406a of the middle panel 106, 206, 306, respectively. The orientation rollers 410a, 410b may also be supported by a frame or the like coupled to the respective shafts 444 to support the orientation rollers 410a, 410b during rotation. In one example, the width of the orientation rollers 410a, 410b in the Y direction is at least equal to the width W of the structural panel assembly 100, 200, 300.

[0052] In one example, at least one thickness setting system 412 includes a first thickness setting system 412a and a second thickness setting system 412b. The first thickness setting system 412a is located upstream of the second thickness setting system 412b in the direction D of the flow of the materials 402a, 404a, 406a through the manufacturing system 400. Each of the first thickness setting system 412a and the second thickness setting system 412b includes a first pressure roller 446, a second pressure roller 448, and a friction plate 450. The first pressure roller 446 and the second pressure roller 448 may each include a third roller center hole 452 that receives an axis 454, etc., so that each of the pressure rollers 446, 448 can rotate. The pressure rollers 446, 448 have a substantially smooth outer circumference and are controlled via the controller 418, for example, to apply pressure to a corresponding one of the material 402a for the top panel 102 and the material 402b for the bottom panel 104. It should be noted that in other examples, the pressure rollers 446, 448 may be fixed relative to the friction plate 450 at a predetermined panel thickness PT and supported on a frame or the like to be rotatable. In one example, the width of the pressure rollers 446, 448 in the Y direction is at least equal to the width W of the structural panel assembly 100, 200, 300.

[0053] The friction plate 450 is rectangular and has a width in the Y direction at least equal to the width W of the structural panel assembly 100, 200, 300. The axial length FL of the friction plate 450 in the X direction is about one to five times the peak-to-peak distance PD, and in one example, is about 50 millimeters (mm) to about 500 millimeters (mm). Generally, the axial length FL is predetermined to enable the welding system 414 to couple the material 402a associated with the top panel 102 to the material 406a associated with the bottom panel 104. The friction plate 450 is substantially planar and cooperates with the pressure rollers 446, 448 to ensure that the materials 402a, 404a, 406a used to form the structural panel assembly 100, 200, 300 are welded by the welding system 414 at a predetermined panel thickness PT. Additionally, the friction plate 450 cooperates with the pressure rollers 446 , 448 to compress the material 402a of the top panel 102 and the material 404a of the bottom panel 104 to the material 406a of the middle panel 106 , 206 , 306 to ensure adequate contact for forming the weld 120 , 320 .

[0054] In the example of the first thickness setting system 412a, the pressure rollers 446, 448 are positioned to contact the material 402a associated with the top panel 102, and the friction plate 450 is positioned to contact the material 404a associated with the bottom panel 104. In the example of the second thickness setting system 412b, the pressure rollers 446, 448 are positioned to contact the material 404a associated with the bottom panel 104, and the friction plate 450 is positioned to contact the material 402a associated with the top panel 102. It should be noted that in other examples, this arrangement can be reversed.

[0055] In the example of the first thickness setting system 412a, the first pressure roller 446 is located upstream of the second pressure roller 448 in the direction D of the material 402a, 404a, 406a flowing through the manufacturing system 400. The pressure rollers 446, 448 of the first thickness setting system 412a are positioned opposite the friction plate 450 of the first thickness setting system 412a. The pressure rollers 446, 448 are spaced apart from each other such that the first pressure roller 446 is opposite the first end of the friction plate 450 and the second pressure roller 448 is opposite the second end of the friction plate 450. The pressure rollers 446, 448 and the friction plate 450 of the first thickness setting system 412a cooperate to ensure that the materials 402a, 404a, 406a used to form the structural panel assembly 100, 200, 300 are welded at a predetermined panel thickness PT. In one example, the pressure rollers 446, 448 apply a pressure of about 1.0 pounds per square inch (psi) to about 20 pounds per square inch (psi) to the material 402a of the top panel 102 to compress the material 402a, 404a, 406a toward the friction plate 450 of the first thickness setting system 412a to the panel thickness PT and ensure contact between the materials 402a, 404a, 406a during welding. The pressure values ​​provided are merely examples, as the pressure applied by the pressure rollers 446, 448 is predefined based on the thickness T1 of the intermediate panel 106, 206, 306, the width W of the structural panel assembly 100, 200, 300, and the predetermined amount of compression to achieve contact between the materials 402a, 404a, 406a during welding.

[0056] In the example of the second thickness setting system 412b, the first pressure roller 446 is located upstream of the second pressure roller 448 in the direction D of the material 402a, 404a, 406a flowing through the manufacturing system 400. The pressure rollers 446, 448 of the second thickness setting system 412b are positioned opposite to the friction plate 450 of the second thickness setting system 412b. The pressure rollers 446, 448 are spaced apart from each other such that the first pressure roller 446 is opposite to the first end of the friction plate 450 and the second pressure roller 448 is opposite to the second end of the friction plate 450. The pressure rollers 446, 448 and the friction plate 450 of the second thickness setting system 412b cooperate to ensure that the materials 402a, 404a, 406a used to form the structural panel assembly 100, 200, 300 are welded at a predetermined panel thickness PT. In one example, the pressure rollers 446, 448 apply a pressure of about 1.0 pounds per square inch (psi) to about 20 pounds per square inch (psi) to the material 404a of the bottom panel 104 to compress the material 402a, 404a, 406a toward the friction plate 450 of the second thickness setting system 412b to the panel thickness PT and ensure contact between the materials 402a, 404a, 406a during welding. The pressure values ​​provided are merely examples, as the pressure applied by the pressure rollers 446, 448 is predefined based on the thickness T1 of the intermediate panel 106, 206, 306, the width W of the structural panel assembly 100, 200, 300, and the predetermined amount of compression to achieve contact between the materials 402a, 404a, 406a during welding.

[0057] As the material 402a of the top panel 102, the material 406a of the intermediate panels 106, 206, 306, and the material 404a of the bottom panel 104 pass through the first thickness setting system 412a, the first pressure roller 446 applies pressure to the material 402a associated with the top panel 102 while rotating to move the material 402a toward the friction plate 450, thereby applying pressure to the material 406a associated with the intermediate panels 106, 206, 306, and the material 404a associated with the bottom panel 104. As will be discussed, as the assembly of the materials 402a, 404a, 406a continues to move in the direction D, the welding system 414 welds the material 402a associated with the top panel 102 to the material 406a associated with the intermediate panels 106, 206, 306. The second pressure roller 448 applies pressure to the material 402a associated with the top panel 102 while rotating to maintain the assembly of the materials 402a, 404a, 406a at a predetermined panel thickness PT and ensure contact between the materials 402a, 404a, 406a. As the material 402a of the top panel 102, the material 406a of the intermediate panels 106, 206, 306, and the material 404a of the bottom panel 104 continue to move in the direction D, the materials 402a, 404a, 406a pass through the second thickness setting system 412b. The first pressure roller 446 applies pressure to the material 404a associated with the bottom panel 104 while rotating to move the material 404a toward the friction plate 450, thereby applying pressure to the material 406a associated with the intermediate panels 106, 206, 306 and the material 402a associated with the top panel 102. As will be discussed, the welding system 414 welds the material 404a associated with the bottom panel 104 to the material 406a associated with the intermediate panels 106, 206, 306 as the assembly of materials 402a, 404a, 406a continues to move in the direction D. The second pressure roller 448 applies pressure to the material 404a associated with the bottom panel 104 while rotating to maintain the assembly of materials 402a, 404a, 406a at a predetermined panel thickness PT and to ensure contact between the materials 402a, 404a, 406a.

[0058] In one example, the welding system 414 includes a first welding subsystem 414a and a second welding subsystem 414b. The first welding subsystem 414a cooperates with the first thickness setting system 412a, and the second welding subsystem 414b cooperates with the second thickness setting system 412b. Each of the first welding subsystem 414a and the second welding subsystem 414b includes at least one or more laser welding machines or laser welders 460. Each of the laser welders 460 responds to one or more control signals from the controller 418 to output a laser beam to couple or weld the top panel 102 and the bottom panel 104 to the middle panel 106, 206, 306, respectively.

[0059] Usually, reference Figure 8 , a schematic diagram of a first welding subsystem 414a and a first thickness setting system 412a is shown. Since the first welding subsystem 414a and the first thickness setting system 412a are each identical to the second welding subsystem 414b and the second thickness setting system 412b, respectively, but are oriented approximately 180 degrees for welding the material 404a associated with the bottom panel 104 to the material 406a associated with the middle panel 106, 206, 306, the second welding subsystem 414b and the second thickness setting system 412b will not be discussed in detail herein for the sake of brevity.

[0060] In this example, the first welding subsystem 414a includes three laser welders 460 that are controlled by the controller 418 to move in substantially unison to couple or weld the material 402a to the material 406a. Each of the laser welders 460 includes a light source 462, a reflector 464, an optics 466, and a power source 468. The light source 462 is powered and controlled by the power source 468 and the controller 418 to generate light that enters the resonant cavity 470. The light is expanded and reflected by the reflector 464 through the optics 466 to emerge as a concentrated laser beam 472 focused to a point at the material 402a associated with the top panel 102. Each laser welder 460 is configured to apply a laser beam 472 at a welding location to form a weld to join the material 402a associated with the top panel 102 to the material 406a associated with the intermediate panels 106, 206, 306. Typically, the laser welder 460 can be controlled by the controller 418 to produce a predetermined type of weld at the welding location, including but not limited to a seam weld or a line weld 120, 320. It should be noted that Figure 8 The illustration of laser welding machine 460 is merely exemplary, as light source 462 may be configured as a stand-alone device that stands on the floor, with optical fibers transmitting laser beam 472 from light source 462 to optics 466 for laser welding.

[0061] Typically, the movement of the laser welder 460 is substantially linear in nature, and the laser welder 460 has only one degree of freedom, which is the position of the laser welder 460 along their respective linear paths. In one example, a carriage assembly supported by a linear track and / or a linear bearing can be used to move each of the laser welders 460 along a linear path. The carriage assembly supporting the laser welder 460 can be moved along a linear track and / or a linear bearing by a motor, and the motor responds to one or more control signals from the controller 418. The motor communicates with the controller 418 on a suitable communication architecture that supports the transmission of power, data, etc., including but not limited to a communication bus. In one example, the motor is but not limited to a servo motor, a stepper motor, or other motor, and the rotational output of the motor can be converted into a linear movement of the carriage assembly by a lead screw and nut, a ball screw, a chain and a sprocket, a toothed belt and a pulley, etc. Alternatively, an industrial manufacturing robot can be coupled to the carriage assembly and move the laser welder 460 in response to one or more control signals from the controller 418.

[0062] In such Figure 2 , Figure 3 , Figure 5 and Figure 8 In the example of stitch welding or line welding 120, 320 shown in , the laser welder 460 is controlled to move the laser beam 472 along a predetermined welding path P through the material 402a. In this example, the laser welder 460 includes an actuator 474, which responds to one or more control signals from the controller 418 to move the laser welder 460 along the welding path P. The actuator 474 is any suitable actuator, including but not limited to a servo motor, a stepper motor, etc. In this example, the welding path P is defined as being transverse or oblique to the direction of travel D of the materials 402a, 404a, 406a through the manufacturing system 400. In one example, the welding path P of the laser welder 460 is defined as a pitch angle θ relative to the Y direction. The pitch angle θ is defined by the following equation:

[0063]

[0064] Wherein, PD is a predetermined peak distance defined between adjacent peaks 112, 212, 312; N is the number of laser welders 460; and W is a predefined width W of the resulting structural panel assembly 100, 200, 300. In general, the pitch angle defines a welding path P of the laser welder 460 relative to the transverse or Y direction. As the laser welder 460 moves along the welding path P, the laser welder 460 is controlled by the controller 418 to output a laser beam 472 to weld the material 402a associated with the top panel 102 to the material 406a associated with the middle panel 106, 206, 306. In general, the position of each of the laser welders 460 in the X direction (x coordinate) and the Y direction (y coordinate) is known from a position sensor (including but not limited to an encoder) associated with the actuator 474. Each of the laser welders 460 is also in communication with the controller 418 to transmit the position of the laser welder 460 in the (x, y) coordinate to the controller 418.

[0065] Refer to Figure 6, the sensor system 416 includes one or more sensing devices 416a-416n that sense observable conditions of the manufacturing system 400. In various embodiments, the sensing devices 416a-416n include, but are not limited to, optical cameras (e.g., forward, 360 degrees, backward, sideways, stereo, etc.), odometer sensors (e.g., encoders), and / or other sensors that can be used in conjunction with the systems and methods of the present subject matter. In one example, the sensing devices 40a-40n include a first optical camera 416a and a second optical camera 416b. Typically, the first optical camera 416a and the second optical camera 416b are each stereo camera components capable of capturing stereo images with depth information. For example, the first optical camera 416a and the second optical camera 416b can each include a stereo camera having two or more lenses and an image sensor, the image sensor being arranged to capture a stereo image with depth information about the manufacturing system 400. In this example, the first optical camera 416a is a stereo camera assembly for capturing images of the assembly of materials 402a, 404a, 406a as the materials are welded by the first welding subsystem 414a. Typically, the first optical camera 416a is mounted via a frame or other support structure to observe the peaks 112, 212, 312 and the laser welder 460 as the laser welder 460 welds the material 402a associated with the top panel 102 to the material 406a associated with the middle panel 106, 206, 306. The second optical camera 416b is a stereo camera assembly for capturing images of the assembly of materials 402a, 404a, 406a as the materials are welded by the second welding subsystem 414b. Typically, the second optical camera 416b is mounted via a frame or other support structure to observe the valleys 114, 214, 314 and the laser welder 460 as the laser welder 460 welds the material 404a associated with the bottom panel 104 to the material 406a associated with the middle panel 106, 206, 306. By observing the peaks 112, 212, 312 and valleys 114, 214, 314 of the material 406a associated with the middle panel 106, 206, 306 and the laser welder 460 of the welding system 414, image data from the optical cameras 416a, 416b can be used to determine whether the laser welder 460 is welding the material 402a, 404a associated with a corresponding one of the top panel 102 and the bottom panel 104 to the peaks 112, 212, 312 and valleys 114, 214, 314 of the material 406a associated with the middle panel 106, 206, 306, respectively. The images may be captured by the optical cameras 416a, 416b according to various timing or other considerations. In some examples, the optical cameras 416a, 416b may continuously capture images (based on one or more control signals from the controller 418) as the materials 402a, 404a, 406a move through the manufacturing system 400.

[0066] It should be noted that while two optical cameras 416a, 416b are shown and described herein, the sensor system 416 may include any number of optical cameras to observe the manufacturing system 400. Furthermore, while described herein as including a stereo camera assembly, the optical cameras 416a, 416b may include a single camera assembly or some other type of sensor capable of providing real-time information about the location of the peaks 112, 212, 312 and valleys 114, 214, 314 of the material 406a in order to synchronize the movement of the laser welder 460 with the movement of the material 406a. It should also be noted that the sensor system 416 may also be used to confirm the quality of the manufacturing process, or as a quality check, to ensure that the final location of the wire weld 120 relative to the peaks 112, 212, 312 and valleys 114, 214, 314 is uniform and consistent.

[0067] The manufacturing system 400 may also include a cutting system 420. Once the materials 402a, 404a, 406a are welded to a predetermined panel thickness PT by the welding system 414, the cutting system 420 may be used to cut the materials 402a, 404a, 406a into structural panel assemblies 100, 200, 300 having a plurality of assemblies for coupling to the vehicle 10 ( Figure 1 ) of a desired length. Typically, the cutting system 420 is a suitable mechanical cutting system, including but not limited to a shear, a saw, an abrasive cutter, a water jet cutter, a laser cutter, a plasma cutter, or a CNC milling machine. The cutting system 420 trims the continuous output of assembly material 402a, 404a, 406a exiting the second thickness setting system 412b into individual structural panel assemblies 100, 200, 300 suitable for installation into the vehicle 10. In one example, the cutting system 420 responds to one or more control signals from the controller 418 to actuate and cut the material 402a, 404a, 406a to define the structural panel assembly 100, 200, 300.

[0068] In the example of the structural panel assembly 200, the manufacturing system 400 also includes at least one perforated roller 422. The at least one perforated roller 422 can be synchronized with the at least one forming roller 408. In one example, the at least one perforated roller 422 includes a first perforated roller 422a and a second perforated roller 422b. The first perforated roller 422a is opposite to the second perforated roller 422b and is located upstream of the second perforated roller 422b in the travel direction D of the material 406a for the intermediate panel 206. In this example, the first perforated roller 422a is offset from the second perforated roller 422b. The perforated rollers 422a, 422b include a corresponding plurality of perforated teeth 480a, 480b. The perforated teeth 480a of the first perforated roller 422a are shaped to cooperate with the perforated teeth 480b of the second perforated roller 422b, and for example, the perforated teeth 480a can include male perforated teeth, while the perforated teeth 480b include female perforated teeth. In this example, each of the perforating teeth 480a, 480b extends along an axis transverse to the direction of the material 406a of the intermediate material coil 406, so that the opening 220 is substantially perpendicular to the structural panel assembly 200 ( Figure 3 ) extends about the axis of the longitudinal axis L of the intermediate panel 206. The perforated rollers 422a, 422b can each include a perforated center hole 482 that receives an axle 484 or the like to enable each of the perforated rollers 422a, 422b to rotate. When the material 406a of the intermediate material coil 406 passes through the perforated rollers 422a, 422b, the perforated rollers 422a, 422b rotate, and the perforated teeth 480a, 480b cooperate to form an opening 220 in the material 406a associated with the intermediate panel 206. Typically, the perforated teeth 480a, 480b are defined around the circumference of the respective perforated rollers 422a, 422b. The perforated rollers 422a, 422b can also be supported by a frame or the like coupled to the respective axles 484 to support the perforated rollers 422a, 422b during rotation. In one example, the width of the perforated rollers 422a, 422b in the Y direction is at least equal to the width W of the structural panel assembly 200.

[0069] The controller 418 includes at least one processor 490 and a computer-readable storage device or medium 492. The processor 490 can be any custom or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), an application-specific integrated circuit (ASIC) (e.g., a custom ASIC that implements a neural network), a field programmable gate array (FPGA), an auxiliary processor of several processors associated with the controller 418, a semiconductor-based microprocessor (in the form of a microchip or chipset), any combination thereof, or any device generally used to execute instructions. For example, the computer-readable storage device or medium 492 can include volatile and non-volatile storage in read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operating variables when the processor 490 is powered off. The computer readable memory device or medium 492 may be implemented using any of a number of known memory devices, such as a PROM (programmable read-only memory), an EPROM (electrical PROM), an EEPROM (electrically erasable PROM), flash memory, or any other electrical, magnetic, optical, or combination memory device capable of storing data, some of which represents executable instructions used by the controller 418 in controlling the manufacturing system 400. In various embodiments, the controller 418 is configured to implement the instructions of the manufacturing control system 600, as discussed in detail below. In various embodiments, when executed by the processor 490, the instructions receive and process sensor data from the sensor system 416 and data received from other modules associated with the manufacturing system 400 to control at least the laser welding machine 460.

[0070] As about Fig. 9 More details are shown and reference is made to Figure 1-Figure 8 , the data flow diagram illustrates an embodiment of a control module 602 of a manufacturing control system 600, which may be implemented by or incorporated into the controller 418 and / or the processor 490. In various embodiments, the control module 602 may be implemented as one or more sub-modules. Various embodiments of the control module 602 according to the present disclosure may include any number of sub-modules embedded within the controller 418. It is understood that Fig. 9 The submodules shown in the figure can be combined and / or further divided to control the laser welding machine 460. In addition, the data input of the control module 602 can be obtained from the sensor system 416 ( Figure 6 and Figure 8), received from other control modules (not shown) associated with the manufacturing system 400, and / or determined / modeled by other submodules (not shown) within the controller 418. In various embodiments, the control module 602 includes an intermediate panel monitoring module 610, a welding machine speed determination module 612, a speed data repository 613, and a laser welding machine control module 614.

[0071] The intermediate panel monitoring module 610 receives sensor data 616 as input. In one example, the sensor data 616 includes image data from the first optical camera 416a and the second optical camera 416b. The intermediate panel monitoring module 610 processes the sensor data 616 and determines the locations of the peaks 112, 212, 312 and the laser welder 460 in the image data from the first optical camera 416a. For example, the intermediate panel monitoring module 610 determines the locations of the peaks 112, 212, 312 in (x, y) coordinates and the location of the laser welder 460 in (x, y) coordinates based on the image data. The intermediate panel monitoring module 610 sets the locations of the peaks 112, 212, 312 in (x, y) coordinates as peak position data 618 for the welding machine speed determination module 612. The peak position data 618 is the observed position of the peak 112, 212, 312 of the material 406a associated with the intermediate panel 106, 206, 306 in the X direction and the Y direction or in (x, y) coordinates. The intermediate panel monitoring module 610 processes the sensor data 616 and determines the position of the laser welder 460 of the first welding subsystem 414a in the image data from the first optical camera 416a. The intermediate panel monitoring module 610 sets the position of the laser welder 460 of the first welding subsystem 414a in (x, y) coordinates as the first welder position data 619 for the welder speed determination module 612. The first welder position data 619 is the observed position of the laser welder 460 of the first welding subsystem 414a in the X direction and the Y direction or in (x, y) coordinates.

[0072] The intermediate panel monitoring module 610 also processes the sensor data 616 and determines the positions of the valleys 114, 214, 314 and the laser welder 460 in the image data from the second optical camera 416b. For example, the intermediate panel monitoring module 610 determines the positions of the valleys 114, 214, 314 in (x, y) coordinates and the position of the laser welder 460 in (x, y) coordinates based on the image data. The intermediate panel monitoring module 610 sets the positions of the valleys 114, 214, 314 in (x, y) coordinates as valley position data 620 for the welder speed determination module 612. The valley position data 620 is the observed position of the valleys 114, 214, 314 of the material 406a associated with the intermediate panel 106, 206, 306 in the X direction and the Y direction or in the (x, y) coordinates. The middle panel monitoring module 610 processes the sensor data 616 and determines the position of the laser welder 460 of the second welding subsystem 414b in the image data from the second optical camera 416b. The middle panel monitoring module 610 sets the position of the laser welder 460 of the second welding subsystem 414b in the (x, y) coordinates as the second welder position data 621 for the welder speed determination module 612. The second welder position data 621 is the observed position of the laser welder 460 of the second welding subsystem 414b in the X direction and the Y direction or in the (x, y) coordinates. In one example, the positions of the peaks 112, 212, 312 and the laser welder 460 in the images captured by the first optical camera 416a and the second optical camera 416b can be determined by a pattern recognition algorithm that identifies the differences in brightness, color and / or saturation between adjacent pixel groups in the captured images to infer the positions of the peaks 112, 212, 312 and the laser welder 460, however, other methods may be used.

[0073] The speed data repository 613 stores data of the current speed of the laser welder 460 of the first welding subsystem 414a and the second welding subsystem 414b, and in one example, the speed data repository 613 stores current speed data 623. In one example, the current speed data 623 is populated by the welding machine speed determination module 612.

[0074] The welding machine speed determination module 612 receives as input sheet data 622. The sheet data 622 is data associated with the structural panel assembly 100, 200, 300 manufactured by the manufacturing system 400. For example, the sheet data 622 includes a predetermined peak distance PD defined between adjacent peaks 112, 212, 312 and a predetermined width W of the resulting structural panel assembly 100, 200, 300. The sheet data 622 may be received from another module associated with the control module 602 and / or may be received via input from a human-machine interface associated with the manufacturing system 400. The sheet data 622 may also be a predefined or factory-set value that is stored in a data repository associated with the control module 602.

[0075] The welder speed determination module 612 receives as input the laser welder data 624. The laser welder data 624 is data associated with the laser welder 460 of each of the first welding subsystem 414a and the second welding subsystem 414b. In one example, the laser welder data 624 includes N or the number of laser welders 460 associated with each of the first welding subsystem 414a and the second welding subsystem 414b; the position of the laser welder 460 of the first welding subsystem 414a from the position sensor associated with each of the laser welders 460; the position of the laser welder 460 of the second welding subsystem 414b from the position sensor associated with each of the laser welders 460; the initial start position of the laser welder 460 of each of the first welding subsystem 414a and the second welding subsystem 414b; and the maximum position of the laser welder 460 of each of the first welding subsystem 414a and the second welding subsystem 414b. The number of laser welders 460 associated with each of the first welding subsystem 414a and the second welding subsystem 414b may be received from another module associated with the control module 602 and / or may be received via input from a human-machine interface associated with the manufacturing system 400. The number of laser welders 460 associated with each of the first welding subsystem 414a and the second welding subsystem 414b may also be a predefined or factory-set value that is stored in a data repository associated with the control module 602. The position of the laser welder 460 of the first welding subsystem 414a and the position of the laser welder 460 of the second welding subsystem 414b may be received from a position sensor of an actuator 474 associated with the laser welder 460 of each of the first welding subsystem 414a and the second welding subsystem 414b. The starting position and maximum position of each of the laser welders 460 of each of the first welding subsystem 414a and the second welding subsystem 414b may be received from another module associated with the control module 602 and / or may be received via input from a human-machine interface associated with the manufacturing system 400. The starting position and maximum position of each of the laser welders 460 of each of the first welding subsystem 414a and the second welding subsystem 414b may also be predefined or factory set values ​​that are stored in a data repository associated with the control module 602. In one example, for a structural panel assembly 100, 200, 300 having a width W (or Y=10), the starting position of the first welding subsystem 414a and the starting position of the second welding subsystem 414b are approximately 10 millimeters (mm) in the Y direction, with Y=0 at an edge E of the structural panel assembly 100, 200, 300.In one example, for a structural panel assembly 100, 200, 300 having a width W (or W-10), the maximum position of the first welding subsystem 414a and the maximum position of the second welding subsystem 414b in the Y direction is approximately the width W minus 10 millimeters (mm).

[0076] Based on the position of the laser welder 460 associated with the first welding subsystem 414a, the welder speed determination module 612 determines whether the laser welder 460 is in the starting position. Based on the position of the laser welder 460 associated with the second welding subsystem 414b, the welder speed determination module 612 determines whether the laser welder 460 is in the starting position of the second welding subsystem 414b. Based on the laser welders 460 of the first welding subsystem 414a and the second welding subsystem 414b being in the starting position, the welder speed determination module 612 determines or calculates the pitch angle θ of the welding path P of the laser welder 460 of each of the first welding subsystem 414a and the second welding subsystem 414b using the above equation (1). The welder speed determination module 612 receives line data 626 as input. The line data 626 is data associated with the manufacturing system 400, and in one example, includes the rotational speeds of the top material coil 402, the bottom material coil 404, and the middle material coil 406. Typically, each of the top material coil 402, the bottom material coil 404, and the middle material coil 406 rotates at the same speed so that the materials 402a, 404a, 406a are fed to the thickness setting system 412 and the welding system 414 at substantially the same speed. In one example, the line data 626 is approximately one foot per second. The line data 626 may be received from another module associated with the control module 602 and / or may be received via an input of a human-machine interface associated with the manufacturing system 400. The line data 626 may also be a predefined or factory-set value that is stored in a data repository associated with the control module 602.

[0077] The welding machine speed determination module 612 determines or calculates the baseline speed of the laser welding machine 460 for each of the first welding subsystem 414a and the second welding subsystem 414b based on the determined pitch angle θ and the line data 626. In one example, the baseline speed of the laser welding machine 460 is calculated using the following equation:

[0078]

[0079] Wherein, BaseSpeed ​​is the baseline speed of the laser welder 460; S is the rotation speed of the top material coil 402, the bottom material coil 404, and the middle material coil 406 provided by the line data 626; and θ is the pitch angle determined using equation (1). The welder speed determination module 612 sets the baseline speed determined using equation (2) as the speed data 628 of the laser welder control module 614, and stores the speed data 628 as the current speed data 623. The speed data 628 is the speed used by the actuator 474 to move the laser welder 460 along the welding path P.

[0080] Based on the position of the laser welder 460 associated with the first welding subsystem 414a, the welder speed determination module 612 determines whether the laser welder 460 is in the maximum position. Based on the position of the laser welder 460 associated with the second welding subsystem 414b, the welder speed determination module 612 determines whether the laser welder 460 is in the maximum position of the second welding subsystem 414b. If the laser welder 460 of the first welding subsystem 414a is not in the maximum position, the welder speed determination module 612 receives the peak position data 618 and the first welder position data 619 as inputs. The welder speed determination module 612 subtracts the X position (or x coordinate) of the peak 112, 212, 312 determined from the peak position data 618 from the X position (or x coordinate) of the position of the laser welder 460 of the first welding subsystem 414a to determine an error value. Generally, the error value indicates whether there is an error in the X direction between the position of the peak 112, 212, 312 and the position of the laser welder 460, such that the laser welder 460 is ahead of the peak 112, 212, 312 (or ahead of the material 406a; negative error value) or the laser welder 460 is behind the peak 112, 212, 312 (or behind the material 406a; positive error value). If the laser welder 460 of the second welding subsystem 414b and the second welding subsystem 414b are not in the maximum position, the welder speed determination module 612 receives the valley position data 620 and the second welder position data 621 as inputs. The welder speed determination module 612 subtracts the X position (or x coordinate) of the valley 114, 214, 314 determined from the valley position data 620 from the X position (or x coordinate) of the position of the laser welder 460 of the second welding subsystem 414b to determine the error value. Typically, the error value indicates whether there is an error in the X direction between the position of the valley 114, 214, 314 and the position of the laser welder 460, such that the laser welder 460 is ahead of the valley 114, 214, 314 (or ahead of the material 406a; negative error value) or the laser welder 460 is behind the valley 114, 214, 314 (or behind the material 406a; positive error value).

[0081] Based on determining that there is an error in the position of the laser welder 460 of the first welding subsystem 414a and / or the second welding subsystem 414b, the welding machine speed determination module 612 applies a proportional, integral, and derivative (PID) algorithm to determine a correction term. In one example, the PID algorithm is defined by the following equation:

[0082]

[0083] Among them, u(t) is the correction term; K p is the proportional gain, which is a predefined factory setting value; K i is an integral gain, which is a predefined factory setting value; e(t) is an error value between the X position of the peaks 112, 212, 312 and the X position of the laser welder 460 of the first welding subsystem 414a or between the X position of the valleys 114, 214, 314 and the X position of the laser welder 460 of the second welding subsystem 414b; t is time, which can be obtained from the sensor data 616 or from another module associated with the control module 602; and K d is the derivative gain, which is a predefined factory set value.

[0084] The welding machine speed determination module 612 queries the speed data repository 613 and retrieves the current speed data 623. The welding machine speed determination module 612 adds the correction term determined by the PID algorithm to the current speed to determine a new speed for the actuator 474 to move the laser welder 460 of the first welding subsystem 414a and / or the second welding subsystem 414b. The welding machine speed determination module 612 sets the new speed for the actuator 474 to move the laser welder 460 of the first welding subsystem 414a and / or the second welding subsystem 414b as the speed data 628 of the laser welder control module 614. The welding machine speed determination module 612 stores the new speed in the speed data repository 613 as the current speed data 623 of the laser welder 460 of each of the first welding subsystem 414a and the second welding subsystem 414b.

[0085] The laser welder control module 614 receives as input the speed data 628 for the actuator 474 to move the laser welder 460 of the corresponding one of the first welding subsystem 414a and the second welding subsystem 414b. Based on the speed data 628 received for the laser welder 460 of the first welding subsystem 414a, the laser welder control module 614 outputs the first control data 632. The first control data 632 is data of one or more control signals for the actuator 474 of the first welding subsystem 414a to move the laser welder 460 of the first welding subsystem 414a at a determined speed. Based on the speed data 628 received for the laser welder 460 of the second welding subsystem 414b, the laser welder control module 614 outputs the second control data 634. The second control data 634 is data of one or more control signals for the actuator 474 of the second welding subsystem 414b to move the laser welder 460 of the second welding subsystem 414b at a determined speed.

[0086] Reference now Fig.10 And continue to refer to Figure 1-Figure 9 , the flow chart shows that according to the present disclosure, Fig. 9 Method 700 is performed by the manufacturing control system 600 of the embodiment of the present invention. In one example, the method 700 is performed by the processor 490 of the controller 418. It is understood from the present disclosure that the order of operations within the method 700 is not limited to the following. Fig.10 , but may be performed in one or more altered orders where applicable and in accordance with the present disclosure. In various embodiments, method 700 may be scheduled to run based on one or more predetermined events, and / or may run continuously during operation of manufacturing system 400.

[0087] The method begins at 702. At 704, the method 700 receives and processes the sensor data 616. For example, the method 700 receives and processes the image data from the optical cameras 416a, 416b. At 706, the method 700 determines whether the laser welders 460 of the first welding subsystem 414a and the second welding subsystem 414b are in the initial starting position. If true, the method 700 proceeds to 708. Otherwise, the method 700 loops to 704.

[0088] At 708, method 700 uses Fig.11The method 800 discussed determines a baseline speed for the actuator 474 to move the laser welder 460 of the first welding subsystem 414a and the second welding subsystem 414b. At 710, the method 700 outputs one or more control signals to the actuator 474 to move the laser welder 460 at the baseline speed. At 712, the method 700 receives and processes image data from the optical cameras 416a, 416b. At 714, the method 700 determines whether the laser welder 460 of the first welding subsystem 414a and the second welding subsystem 414b has reached a maximum position. If true, the method 700 ends at 716.

[0089] Otherwise, at 718, the method 700 determines the locations of the peaks 112, 212, 312 and valleys 114, 214, 314 based on the sensor data 616. At 720, the method 700 uses the information about Fig.12 The method 900 discussed adjusts the speed of the laser welder 460 for the actuator 474 to move the first welding subsystem 414a and / or the second welding subsystem 414b based on the locations of the peaks 112, 212, 312 and valleys 114, 214, 314, respectively. The method 700 loops to 714.

[0090] refer to Fig.11 And continue to refer to Figure 1-Figure 9 , the flow chart shows that according to the present disclosure, Fig. 9 Method 800 is performed by the manufacturing control system 600 of the embodiment of the present invention. In one example, the method 800 is performed by the processor 490 of the controller 418. It is understood from the present disclosure that the order of operations within the method 800 is not limited to the following. Fig.11 Rather, the steps are not performed in the order shown in the drawings, but may be performed in one or more altered orders where applicable and in accordance with the present disclosure.

[0091] In one example, at 810, the method 800 begins a baseline speed determination. At 812, the method 800 receives and processes the laser welder data 624 and the line data 626. At 814, the method 800 determines or calculates the pitch angle θ of the laser welder 460 of the first welding subsystem 414a and the second welding subsystem 414b using equation (1). At 816, the method calculates a baseline speed for the actuator 474 to move the laser welder 460 of the first welding subsystem 414a and the second welding subsystem 414b using equation (2). At 818, the method 800 stores the calculated baseline speed as the current speed of the laser welder 460 of the first welding subsystem 414a and the second welding subsystem 414b for the actuator 474 to move. The method 800 ends at 820.

[0092] refer to Fig.12 And continue to refer to Figure 1-Figure 9, the flow chart shows that according to the present disclosure, Fig. 9 In one example, the method 900 is executed by the processor 490 of the controller 418. It is understood from the present disclosure that the order of operations within the method 900 is not limited to the following. Fig.12 Rather, the steps are not performed in the order shown in the drawings, but may be performed in one or more altered orders where applicable and in accordance with the present disclosure.

[0093] At 902, the method 900 begins speed adjustment of the laser welder 460. At 904, the method 900 determines the x-positions of the peaks 112, 212, 312 and the valleys 114, 214, 314 based on the sensor data 616. At 906, the method 900 subtracts the x-positions of the peaks 112, 212, 312 from the x-positions of the laser welder 460 of the first welding subsystem 414a to determine an error value for the first welding subsystem 414a, and subtracts the x-positions of the valleys 114, 214, 314 from the x-positions of the laser welder 460 of the second welding subsystem 414b to determine an error value for the second welding subsystem 414b. At 908, the method determines whether the error values ​​of the respective welding subsystems 414a, 414b are equal to zero. If true, the method 900 ends at 910.

[0094] Otherwise, at 912, the method 900 applies the PID algorithm of equation (3) to determine or calculate the correction term for the welding subsystem 414a, 414b for which the error value is not equal to zero. At 914, the method 900 retrieves the current speed for the corresponding actuator 474 to move the laser welder 460, and adds the correction term to the current speed to calculate a new speed for the actuator 474 to move the corresponding laser welder 460. At 916, the method 900 stores the new speed for the actuator 474 to move the corresponding laser welder 460 as the current speed. The method 900 ends at 910.

[0095] Thus, the structural panel assembly 100, 200, 300 provides support for the occupants while also providing protection for one or more batteries associated with the vehicle 10. In this regard, the intermediate panels 106, 206, 306 include or act as a truss structure in both the longitudinal direction (along the longitudinal axis L) and the transverse direction or a direction substantially perpendicular to the longitudinal axis L. In addition, the structural panel assembly 200 provides reduced weight while still providing support and protection. Due to the longitudinal arrangement of the peaks 312 and valleys 314, the structural panel assembly 300 enables the structural panel assembly 300 to be used with vehicles having a larger width. The manufacturing system 400 is capable of efficiently forming the structural panel assemblies 100, 200, 300. In addition, by employing optical cameras 416a, 416b, the movement of the laser welder 460 is synchronized with the position of the peaks 112, 212, 312 and the valleys 114, 214, 314 to ensure that the materials 402a, 404a, 406a are properly welded together. Furthermore, because the manufacturing system 400 produces the structural panel assemblies 100, 200, 300 in a continuous process (rather than a batch process), the manufacturing system 400 is more efficient. In addition, the gaps existing between the peaks 112, 212, 312 and valleys 114, 214, 314 can be easily filled with materials, including but not limited to expanding foam, etc., to enhance sound damping, strength and / or provide thermal insulation. In addition, the ability to maintain a constant force to close the gaps between the materials 402a, 404a, 406a using the first thickness setting system 412a and the second thickness setting system 412b during laser welding by the laser welder 460 increases the robustness of the manufacturing of the structural panel assemblies 100, 200, 300.

[0096] It should be noted that while the laser welder 460 is described herein as being used to weld the structural panel assemblies 100, 200, 300 together, in other embodiments, resistance spot welding may be used to weld the top panel 102 and the middle panel 106, 206, 306 or the bottom panel 104 and two of the middle panels 106, 206, 306, and the laser welder 460 may be used to weld the other of the top panel 102 or the bottom panel 104 to the middle panel 106, 206, 306. Furthermore, while the manufacture of the structural panel assembly 300 is described herein as employing the sensor system 416 to synchronize the laser welder 460, in other embodiments, the structural panel assembly 300 may be manufactured without the sensor system 416, if desired.

[0097] 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 vehicle comprising: a frame defining an opening; as well as a structural panel assembly coupled to the opening, the structural panel assembly comprising: First material; a second material opposite to the first material; and A third material is located between the first material and the second material, the third material having a wavy shape including peaks and valleys, and the first material is coupled to the peaks and the second material is coupled to the valleys.

2. The vehicle according to claim 1, wherein: The first material, the second material and the third material are composed of metal or metal alloy.

3. The vehicle according to claim 2, wherein: The first material is welded to the peaks and the second material is welded to the valleys.

4. The vehicle according to claim 3, wherein: The first material is welded to the peaks via a plurality of intermittent welds, and the second material is welded to the valleys via a second plurality of intermittent welds.

5. The vehicle according to claim 1, wherein: The structural panel assembly has a longitudinal axis, and the peaks and valleys each extend along an axis parallel to the longitudinal axis.

6. The vehicle according to claim 1, wherein: The structural panel assembly has a longitudinal axis, and the peaks and valleys each extend along an axis perpendicular to the longitudinal axis.

7. The vehicle according to claim 1, wherein: The third material includes a plurality of openings.

8. The vehicle according to claim 7, wherein: The plurality of openings are defined along walls interconnecting the peaks and the valleys.

9. The vehicle of claim 1, wherein: The opening separates a passenger compartment from a storage compartment for one or more batteries associated with the vehicle.

10. A system for manufacturing the structural panel assembly of claim 1, comprising: a pair of forming rollers configured to receive the third material to impart the wavy shape including the peaks and the valleys to the third material; a sensor that observes at least one of the peaks and the valleys; as well as A controller having a processor configured to: One or more control signals are output based on the observation of the peak to control movement of a welding machine relative to the first material to weld the first material to the third material at the peak.

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