Fixtureless Robot Assembly

Abstract

The computing system may direct a first robotic arm to a first position based on a first set of coordinates. The computing system may engage the first robotic arm with a first structure based on the first position of the first robotic arm. Further, the computing system may direct the first robotic arm to a second position based on a second set of coordinates, thereby bringing the first structure into joint proximity with the second structure in the absence of a fixture holding the first structure and in the absence of a fixture holding the second structure, wherein the first structure is configured to join with the second structure when the first and second structures are in joint proximity, the joint proximity being a proximity that allows the first and second structures to join together.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Application No. 62 / 938,921, entitled "FIXTURELESS ROBOTIC ASSEMBLY," filed November 21, 2019, and U.S. Patent Application No. 16 / 950,802, entitled "FIXTURELESS ROBOTIC ASSEMBLY," filed November 17, 2020, the contents of which are expressly incorporated by reference in their entireties herein.

[0002] The present disclosure relates to robotic devices, and more particularly, to techniques for fixtureless assembly using robotic devices. [Background technology]

[0003] Vehicles such as cars, trucks, and airplanes are made up of many individual structural components joined together to form the body, frame, interior and exterior surfaces, etc. These structural components give the car, truck, or airplane its shape and allow it to properly respond to the many different types of forces that are generated or caused by various maneuvers such as accelerating and braking. These structural components also provide support. Structural components of various sizes and shapes may be incorporated into an automobile to provide interfaces between panels, extrusions, and / or other structures, for example. As such, structural components are an integral part of the vehicle.

[0004] Most structural components must be joined to other structural components in a safe and well-designed manner. Modern automotive factories rely heavily on robotic assembly of structural components. However, robotic assembly of automotive components requires the use of fixtures. In an automotive factory, each part of the car that is assembled using robots needs its own fixture. Since a car has many individual parts, it requires many fixtures. In fact, a modern automotive chassis is made up of thousands of assembly parts, each of which needs its own assembly fixture. However, fixtures are very expensive. In fact, it is not uncommon for a single fixture for an automotive part to cost between $300,000 and $500,000. The cost of fixtures used in an automotive factory is a large percentage of the overall factory cost. As a result, building an automotive factory requires huge capital investments, and hundreds of thousands of cars must be manufactured and sold to make a profit, let alone recover the initial investment and break even.

[0005] In addition to their enormous cost, fixtures can only be used for the specific parts they are designed for. Therefore, if the parts are changed in any way, for example, if the design of a car model is updated, a whole new fixture must be designed and manufactured. This makes the process of changing and updating car models very costly and time-consuming. As a result, car models are not updated frequently, for example, only once every 5 or 6 years or more. Also, due to this high cost and lack of flexibility, the automotive industry is considering adopting common structures across vehicle models, such as using the same subframe for car models and SUV models. However, this commonality can impose severe constraints on the design of each vehicle that is forced to share the structure. As a result, vehicles on the road start to look more and more similar, leaving consumers with fewer clear choices.

[0006] Since the dawn of robotic assembly of automobiles, auto manufacturers have unquestionably relied on fixtures. This unquestioned reliance has, in part, resulted in an auto industry dominated by a relatively small number of manufacturers who can invest the huge amounts of capital required to build a modern automobile factory, produce and sell hundreds of thousands of units of a particular automobile model in that factory each year for five or more years, and begin to recoup their initial investment and generate profits. This unquestioned reliance has also resulted in limited consumer choice as cars become more and more similar with each passing year. Summary of the Invention

[0007] In contrast to traditional automotive manufacturing, the present disclosure contemplates eliminating reliance on fixtures as part of a new approach to assembling vehicle structures and other multi-part structures. Such assembly operations may include joining two or more structures (e.g., additively manufactured structures such as nodes), parts, components, etc. In joining multiple structures, at least a portion of a vehicle may be assembled. For example, joining multiple structures may assemble at least a portion of a vehicle's body, frame, chassis, panels, etc. Advantageously, the present disclosure describes such assembly operations by controlling a set of robots to join structures without the use of fixtures. The structures joined by the set of robots may be additively manufactured.

[0008] Because vehicles should be safe and reliable, approaches to accurately perform various assembly operations associated with the production of vehicles may be beneficial. Such approaches to various assembly operations may be performed by at least one robotic device (hereinafter robot) that may be directed via a set of instructions to cooperate in assembling at least a portion of the vehicle (e.g., body, chassis, frame, panels, etc.). Accordingly, a controller and / or other processing system may implement various techniques for generating and / or executing instructions for the at least one robot to orient the at least one robot to one or more positions suitable for performing the various assembly operations.

[0009] This disclosure describes techniques and approaches for directing a set of robots to join at least two structures without the use of fixtures during the assembly of at least a portion of a vehicle. Such techniques and approaches may be implemented through various systems, methods, apparatus, and / or computer-readable media described herein.

[0010] As an example, the computing system may orient a first robotic arm to a first location based on a first set of coordinates. The computing system may engage the first robotic arm with a first structure based on the first location of the first robotic arm. Further, the computing system may orient the first robotic arm to a second location based on a second set of coordinates, where the first structure is brought into mating proximity with the second structure in the absence of a fixture holding the first structure and in the absence of a fixture holding the second structure, the first structure being configured to be mated with the second structure when the first and second structures are in mating proximity, the mating proximity being a proximity that allows the first and second structures to be mated together.

[0011] It will be appreciated that other aspects of the mechanism for achieving fixtureless assembly of at least a portion of a vehicle and other multi-part structures using a set of robots, including joining with structures additively manufactured by a set of fixtureless robots, will be readily apparent to those skilled in the art from the following detailed description. Several embodiments are shown and described herein by way of example. As will be realized by those skilled in the art, the disclosed subject matter is capable of other different embodiments and its several details can be modified in other various respects, all without departing from the present disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive. [Brief description of the drawings]

[0012] [Figure 1A] 1 shows an example of a fixture as known in the art of automotive manufacturing. [Figure 1B] 1 shows an example of a fixture as known in the art of automotive manufacturing. [Figure 1C] 1 shows an example of a fixture as known in the art of automotive manufacturing. [Figure 1D] 1 shows an example of a fixture as known in the art of automotive manufacturing. [Figure 1E] 1 shows an example of a fixture as known in the art of automotive manufacturing. [Diagram 2] 1 illustrates an exemplary embodiment of certain aspects of a direct metal deposition (DMD) 3D printer. [Diagram 3] FIG. 1 shows a conceptual flow diagram of a 3D printing process using a 3D printer. [Figure 4A] 1 illustrates an exemplary powder bed fusion (PBF) system at different stages of operation. [Figure 4B] 1 illustrates an exemplary powder bed fusion (PBF) system at different stages of operation. [Figure 4C] 1 illustrates an exemplary powder bed fusion (PBF) system at different stages of operation. [Figure 4D]1 illustrates an exemplary powder bed fusion (PBF) system at different stages of operation. [Diagram 5] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to assemble at least a portion of a vehicle. [Figure 6A] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6B] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6C] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6D] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6E] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6F] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6G] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6H] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6I] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6J]FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6K] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6L] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6M] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6N] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6O] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6P] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6Q] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6R] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6S] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6T] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6U] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 6V] FIG. 1 illustrates a perspective view of an example assembly system including a plurality of robots configured to perform various example operations for assembling at least a portion of a vehicle. [Figure 7] 1 is a flowchart illustrating an example method of controlling at least one robot for various example operations associated with joining structures in a fixtureless assembly system. [Figure 8] 1 is a flow chart illustrating an example method for directing at least one robot to join at least two structures to assemble at least a portion of a vehicle. [Figure 9] 1 is a flowchart illustrating an example method for having at least one robotic arm position at least one part for interfacing with at least one different part. [Figure 10] FIG. 1 is a block diagram of an example controller processing system configured to direct at least one robot to execute one or more instruction sets for various operations associated with assembly of at least a portion of a vehicle. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The detailed description set forth below in conjunction with the accompanying drawings is intended to provide a description of various exemplary embodiments and is not intended to represent the only embodiments in which the present disclosure may be practiced. The terms "exemplary" and "exemplary" as used throughout this disclosure mean "serving as an example, instance, or illustration" and should not necessarily be construed as preferred or advantageous over other embodiments presented in the present disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the present disclosure to those skilled in the art. However, the present disclosure can be practiced without these specific details. In some cases, well-known structures and components are shown in block diagram form or omitted entirely in order to avoid obscuring various concepts presented throughout the disclosure. Additionally, the drawings may not be drawn to scale, and instead may be drawn in a manner that most effectively highlights various features related to the subject matter being described. Additionally, it should be understood that some elements described in the singular may also be implemented as two or more elements, and some elements described in the plural may also be implemented as a single element. For example, references to "one processor," "one memory," etc., should be understood to include implementations having multiple processors, memories, etc. that perform the described tasks. Similarly, references to "multiple processors," "multiple memories," etc., should be understood to include implementations having a single processor, single memory, etc.

[0014] The automotive industry's unquestioned reliance on fixtures creates significant drawbacks that continue to be simply accepted year after year. Fixtures are specifically designed to fit a single part, and therefore, robotically assembling a complex structure such as an automobile chassis can require thousands of fixtures. Furthermore, changing the design of the chassis requires making an entirely new set of fixtures. Fixtures can be quite complex and expensive to manufacture, so new designs or modifications to current designs can become incredibly expensive.

[0015] In this regard, FIGS. 1A-1E show various examples of fixtures that are conventionally used in manufacturing, including automotive manufacturing. The fixtures are designed to hold and / or position a structure or a portion of a structure, e.g., a portion of a vehicle chassis, during pre-assembly, assembly, and / or post-assembly operations, such as on an assembly line. In doing so, the fixtures can provide a mechanism by which the structure can be engaged and held by a robotic arm. Additionally, the fixtures can provide rigidity to prevent the fixture from moving and / or deflecting during bonding operations. Additionally, the fixtures may act as a reference point for bonding operations to be performed. That is, bonding operations can be performed on the structure under the assumption that the structure is held in a particular position by the fixture. In this manner, the fixtures can hold parts for bonding, position parts for bonding, assist in bonding parts, secure parts for bonding (e.g., if the parts deflect when held by the robot, or lack the rigidity required for various bonding operations), etc.

[0016] The present disclosure describes various techniques and approaches for assembling at least a portion of a vehicle without the use of fixtures. For example, the present disclosure describes one or more robots configured to directly engage a structure, for example, using an end effector of a robotic arm. By eliminating fixtures, the present disclosure may provide various techniques and approaches for assembling a vehicle that are more economical in terms of cost, space, complexity, and / or precision than current vehicle assembly methods.

[0017] 1A illustrates a conventional fixture 100 designed to hold a particular sheet metal panel 102 (e.g., a door panel, a floor panel, etc.) of a vehicle during various assembly operations. In this example, the fixture 100 provides strength and rigidity to the sheet metal panel 102 to prevent unintended movement and / or deflection during joining operations. The fixture 100 includes a number of upper locating brackets 105 that hold a top portion of the sheet metal panel 102, a number of lower locating brackets 107 that hold a bottom portion of the sheet metal panel, and a number of side locating brackets 109 that hold side portions of the sheet metal panel. The fixture 100 also includes a machine part mating surface 111, a part mating surface base plate 113, and a part mating surface top plate 115 that provide rigidity to the sheet metal panel 102. The fixture 100 also includes locating pins 117 that guide the sheet metal panel 102, and a toggle clamp 119 that locks the sheet metal panel in place in the fixture. The fixture 100 also includes a tool support structure 121 for supporting all of the other components of the fixture. Because the fixture 100 is a large and heavy structure, the fixture also includes a hoist ring 123 so that the fixture can be moved and positioned.

[0018] The fixture 100 is designed to be engaged and held in a particular manner by a robotic arm because the panel 102 cannot be directly engaged and held by the robotic arm. The joining operations performed on the panel 102 require the fixture 100 to provide a reference point or frame of reference so that the position of the panel 102 can be assumed and / or estimated. Such assumptions and / or estimates are prone to errors, such as when the panel 102 moves in an unintended manner and / or deflects unintendedly. These errors can accumulate over the assembly process. Thus, relatively large design tolerances may be required, as precision can be difficult to achieve, especially when multiple other parts must be joined to the panel 102.

[0019] 1B shows another conventional fixture 130 used to hold a particular structure of an automobile during a joining operation. In the illustrated example, the fixture 130 is not engaged with the structure, illustrating the typical complexity of the fixture. The fixture 130 includes locating pins 131, an upper base plate 133, a lower base plate 135, and a tool base structure 137. The fixture 130 also includes a box support structure 139 and a crossbeam bracing structure 141 to support all of the components of the fixture. The fixture 130 also includes a mounting clamp 143 for attaching the automobile structure to the fixture.

[0020] 1C shows a side perspective view of another conventional fixture 150. The fixture 150 is secured to the floor to provide fixed and rigid positioning of the structure it holds. Specifically, the fixture 150 has a mounting area 151 to which that particular structure is connected by locating pins 153 and mounting clamps 155, thereby securing the structure to the mounting area 151 for joining operations by one or more robotic interfaces. The fixture 150 also includes a base plate 157, a support structure 159, and a tool base structure 161 to support all other components of the fixture.

[0021] 1D-1E show yet another embodiment of a conventional fixture 170. Fig. 1D is a top perspective view of fixture 170, and Fig. 1E is a side perspective view of the fixture.

[0022] Conventional fixture 170 is configured to engage and hold a panel 172 (e.g., a door panel, a floor panel, etc.). For example, fixture includes a number of fixture blocks 173 for securing panel 172 to the fixture to prevent unintended movement and / or deflection of the panel during various assembly operations. Fixture 170 also includes locating arms 175, locating pins 177, locating brackets 179, and production part mounting fixture 181 for positioning panel 172 during installation operations. Fixture 170 also includes a base plate 183.

[0023] Additive Manufacturing (3D Printing). Additive manufacturing (AM) is advantageously a non-design specific manufacturing technique. AM offers the ability to create composite structures within a part. For example, a node can be created using AM. A node is a structure that can include one or more interfaces used to connect to other spanning components such as tubes, extrusions, panels, other nodes, etc. A node can be configured using AM to include additional features and functions as desired. For example, a node can be printed with one or more ports that allow the node to fasten two parts together by injecting an adhesive, rather than welding multiple parts together as is traditionally done when manufacturing complex products. Alternatively, some components may be connected to the node using a brazing slurry, a thermoplastic, a thermoset, or another connection mechanism, any of which may be used interchangeably in place of an adhesive. Thus, while welding techniques may be appropriate for certain embodiments, additive manufacturing offers significant flexibility in allowing the use of alternative or additional connection techniques.

[0024] A variety of different AM techniques have been used to 3D print components composed of various types of materials. There are numerous available techniques, with more being developed. For example, Directed Energy Deposition (DED) AM systems use directed energy delivered from a laser or electron beam to melt metal. These systems utilize both powder and wire feeding. Wire-fed systems advantageously have higher deposition rates than other prominent AM techniques. Single-pass jetting (SPJ) combines two powder spreaders and one printing unit to spread metal powder and print the structure in a single pass with little or no wasted motion. As another example, the electron beam additive manufacturing process uses an electron beam to melt metal via wire feedstock or sintering in a powder bed in a vacuum chamber. Atomic Diffusion Additive Manufacturing (ADAM) is yet another recently developed technique in which components are printed layer by layer with metal powder in a plastic binder. After printing, the plastic binder is removed and the entire part is sintered at once to the desired metal.

[0025] One of several such AM techniques, as noted, is DMD. Figure 2 shows an exemplary embodiment of certain aspects of a DMD 3D printer 200. The DMD printer 200 uses a feed nozzle 203 that moves in a predetermined direction 219 to propel powder streams 205a and 205b into a laser beam 207 that is directed toward a workpiece 213, which may be supported by a substrate. The feed nozzle 203 may also include a mechanism for flowing a shielding gas 217 to protect the weld area from oxygen, water vapor, or other components.

[0026] The powdered metal may then be melted by the laser 207 in the melt pool region 211 and then bonded to the workpiece 213 as an area of ​​deposited material 209. The dilution area 215 may include an area of ​​the workpiece where the deposited powder is integrated with the local material of the workpiece. The delivery nozzle 203 may be supported by a computer numerically controlled (CNC) robot or gantry, or another computer controlled mechanism. The delivery nozzle 203 may be moved under computer control along a predetermined direction of the substrate multiple times until an initial layer of deposition material 209 is formed over a desired area of ​​the workpiece 213. The delivery nozzle 203 may then scan the area immediately above the previous layer to deposit successive layers until the desired structure is formed. In general, the delivery nozzle 203 may be configured to move on all three axes, and in some cases, to rotate a predetermined amount on its own axis.

[0027] 3 is a flow diagram 300 illustrating an example process for 3D printing. A data model of a desired 3D object to be printed is rendered (operation 303). The data model is a virtual design of the 3D object. Thus, the data model can reflect the geometric and structural features of the 3D object as well as its material composition. The data model may be created using a variety of methods, including CAE-based optimization, 3D modeling, photogrammetry software, and camera imaging. CAE-based optimization may include, for example, cloud-based optimization, fatigue analysis, linear or nonlinear finite element analysis (FEA), and durability analysis.

[0028] The 3D modeling software, in turn, may include one of a number of commercially available 3D modeling software applications. The data model may be rendered, for example, in STL format, using a suitable computer-aided design (CAD) package. STL is an example of a file format associated with commercially available stereolithography-based CAD software. The CAD program may be used to create a data model of the 3D object as an STL file. The STL file may then undergo a process in which errors in the file are identified and resolved.

[0029] Following resolution of any errors, the data model can be "sliced" by a software application known as a slicer to generate a set of instructions for 3D printing the object, the instructions being compatible with and associated with the particular 3D printing technology being utilized (operation 305). Numerous slicer programs are commercially available. Generally, a slicer program converts the data model into a series of individual layers representing thin slices (e.g., 100 μm thick) of the object being printed, along with a file containing printer-specific instructions for 3D printing these successive individual layers to generate an actual 3D printed representation of the data model.

[0030] The layers associated with a 3D printer and the associated printing instructions need not be planar or uniform in thickness. For example, in some embodiments, depending on factors such as the technical sophistication of the 3D printing equipment and the particular manufacturing objectives, the layers of a 3D printed structure may be non-planar and / or may vary in one or more instances with respect to their individual thicknesses.

[0031] A common type of file used to slice a data model into layers is a G-code file, a numerical control programming language that contains instructions for 3D printing an object. The G-code file, or other file comprising the instructions, is uploaded to a 3D printer (operation 307). Since files containing these instructions are typically configured to be operable in a particular 3D printing process, it will be appreciated that many formats of the instruction file are possible, depending on the 3D printing technology being used.

[0032] In addition to printing instructions that dictate what and how the object is to be rendered, appropriate physical materials required for use by the 3D printer in printing the object are provided to the 3D printer using any of a number of conventional, often printer-specific, methods (operation 309). In DMD techniques, for example, one or more metal powders may be provided to layer the structure with such metals or metal alloys. In selective laser melting (SLM), selective laser sintering (SLS), and other PBF-based AM methods (see below), the material may be provided as a powder in a chamber that delivers the powder to the build platform. Depending on the 3D printer, other techniques for providing the printing material may be used.

[0033] Each data slice of the 3D object is then printed using material based on the provided instructions (operation 311). In a 3D printer using laser sintering, a laser scans the powder bed, fusing the powder together where a structure is desired, and avoids scanning areas where the sliced ​​data indicates that nothing will be printed. This process is repeated thousands of times until the desired structure is formed, after which the printed part (structure) is removed from the printer. In fused deposition modeling, a part is printed by applying successive layers of model and support material to a substrate, as described above. In general, any suitable 3D printing technique can be used for the purposes of this disclosure.

[0034] Another AM technique includes Powder Bed Fusion ("PBF"). Like DMD, PBF creates a "build piece" layer by layer. Each layer, or "slice," is formed by depositing a layer of powder and exposing a portion of the powder to an energy beam. The energy beam is applied to a molten area of ​​the powder layer that matches the cross-section of the build piece in the layer. The molten powder cools and fuses to form the slice of the build piece. This process can be repeated to form the next slice of the build piece, and so on. Each layer is deposited on top of the previous layer. The resulting structure is the build piece assembled slice by slice.

[0035] 4A-4D show respective side views of an exemplary PBF system 400 during different stages of operation. As mentioned above, the particular embodiment shown in FIGS. 4A-4D is one of many suitable examples of acceptable PBF systems for use in the present disclosure. It should also be noted that elements in FIGS. 4A-4D and other figures of the present disclosure are not necessarily drawn to scale, but may be drawn larger or smaller for purposes of better illustrating the concepts described herein. The PBF system 400 can include a depositor 401 capable of depositing layers of metal powder, an energy beam source 403 capable of generating an energy beam, a deflector 405 capable of applying the energy beam to melt the powder, and a build plate 407 capable of supporting one or more build pieces, such as build piece 409. The PBF system 400 can also include a build floor 411 disposed within a powder bed receptacle. The walls 412 of the powder bed receptacle generally define the boundaries of the powder bed receptacle, which is sandwiched between the walls 112 from the sides and adjacent to a portion of the build floor 411 below. The build floor 411 can gradually lower the build plate 407 to allow the depositor 401 to deposit the next layer. The entire mechanism can be within a chamber 413 that can enclose other components, thereby protecting the equipment, allowing atmospheric and temperature regulation, and reducing contamination risks. The depositor 401 can include a hopper 415 that contains a powder 417, such as a metal powder, and a leveler 419 that can level the top of each layer of deposited powder.

[0036] With particular reference to Figure 4A, this figure shows the PBF system 400 after a slice of build piece 409 has been melted, but before the next layer of powder is deposited. In fact, Figure 4A shows a point in time where the PBF system 400 has already deposited and melted a slice with multiple layers, e.g., 150 layers, which forms the current state of build piece 409 formed with a slice of, e.g., 150 layers. The multiple layers already deposited create a powder bed 421, which includes deposited but unmelted powder.

[0037] 4B shows the PBF system 400 at a stage where the build floor 411 can be lowered by the powder layer thickness 423. As the build floor 411 is lowered, the build piece 409 and powder bed 421 are lowered by the powder layer thickness 423, such that the tops of the build piece and powder bed are lower than the top of the powder bed receptacle wall 412 by an amount equal to the powder layer thickness. In this way, a space having a constant thickness equal to, for example, the powder layer thickness 423 can be created above the tops of the build piece 409 and powder bed 421.

[0038] FIG. 4C shows the PBF system 400 at a stage where the depositor 401 is positioned to deposit powder 417 in a space created above the top surface of the build piece 409 and the powder bed 421 and bounded by the powder bed receptacle walls 412. In this example, the depositor 401 moves gradually over the defined space while releasing the powder 417 from the hopper 415. The leveler 419 can level the released powder to form a powder layer 425 having a thickness substantially equal to the powder layer thickness 423 (see FIG. 4B). Thus, the powder in the PBF system can be supported by a powder support structure, which can include, for example, the build plate 407, the build floor 411, the build piece 409, the walls 412, etc. It should be noted that the illustrated thickness of the powder layer 425 (i.e., the powder layer thickness 423 (FIG. 4B)) is greater than the actual thickness used in the example involving the previously deposited 450 layers discussed above with reference to FIG. 4A.

[0039] FIG. 4D illustrates the PBF system 400 at a stage following deposition of the powder layer 425 (FIG. 4C), where the energy beam source 403 generates an energy beam 427 and the deflector 405 applies the energy beam to melt the next slice in the build piece 409. In various exemplary embodiments, the energy beam source 403 can be an electron beam source, in which case the energy beam 427 constitutes an electron beam. The deflector 405 can include deflection plates that can generate electric or magnetic fields that selectively deflect the electron beam to cause it to scan across a designated area to be melted. In various embodiments, the energy beam source 403 can be a laser, in which case the energy beam 427 is a laser beam. The deflector 405 can include an optical system that uses reflection and / or refraction to steer the laser beam to scan the selected area to be melted.

[0040] In various embodiments, the deflector 405 can include one or more gimbals and actuators that can rotate and / or translate the energy beam source to position the energy beam. In various embodiments, the energy beam source 403 and / or the deflector 405 can modulate the energy beam, for example, in various embodiments, the energy beam can be modulated by a digital signal processor (DSP).

[0041] 5-10, various embodiments are provided for controlling a robot to assemble at least a portion of a vehicle by joining at least two structures without the use of fixtures. At least one of the at least two structures may be additively manufactured, for example, as described with respect to FIGS. 2, 3, and 4A-D above. In some embodiments, at least one of the at least two structures may be a piece, part, node, component, and / or other additively manufactured structure, which may include two structures that were previously joined. For example, the structure or part may be at least a portion or section associated with a vehicle, such as a vehicle chassis, panel, base piece, body, frame, and / or other vehicle component.

[0042] According to various embodiments, such structures joined in connection with the assembly of a vehicle may be additively manufactured with one or more features that may facilitate or enable various assembly operations (e.g., joining) without the use of a fixture, such as one or more features that prevent or reduce unintended movement of the structure and / or deflection of the structure during one or more fixtureless assembly operations. For example, one or more structures joined in connection with the fixtureless assembly of a vehicle may be additively manufactured with one or more features designed to provide stability, strength, and / or rigidity during various fixtureless assembly operations. Examples of such features may include mesh, honeycomb, and / or lattice substructures, which may be co-printed with the structure (e.g., if the structure is additively manufactured) and may be on the interior and / or exterior of the structure.

[0043] According to various embodiments described herein, an assembly system may include two robots, at least one of which may be positioned to join one structure with another structure without the use of a fixture. Various assembly operations may be performed potentially repeatedly such that multiple structures may be joined to assemble at least a portion of a vehicle (e.g., a vehicle chassis, body, panels, etc.) in a fixtureless manner.

[0044] The first robot may be configured to engage and hold a first structure to which one or more other structures may be joined during various operations performed in connection with fixtureless assembly of at least a portion of a vehicle. For example, the first structure may be a section of a chassis, panel, base piece, body, frame, etc. of a vehicle, while the other structure may be another section of a chassis, panel, base piece, body, frame, etc. of a vehicle.

[0045] Illustratively, a first robot may engage and hold a first structure to be joined with a second structure, and the second structure may be engaged and held by the second robot. Various operations performed with the first structure (e.g., joining the first structure with one or more other structures, which may include two or more previously joined structures) may be performed at least in part within an assembly cell including multiple robots. Thus, at least one of the robots may be directed (e.g., controlled) during fixtureless operations with the first structure to function according to a precision commensurate with the fixtureless operations.

[0046] The present disclosure provides a variety of different embodiments for directing one or more robots at least in part within an assembly system for assembly operations (including pre-assembly and / or post-assembly operations). It will be understood that the various embodiments described herein may be implemented together. For example, an embodiment described with respect to one illustration of the present disclosure may be implemented with another embodiment described with respect to another illustration of the present disclosure.

[0047] Referring first to FIG. 5, this figure illustrates a perspective view of a fixtureless assembly system 500. The fixtureless assembly system 500 may be employed in various operations associated with fixtureless assembly of a vehicle, such as robotic assembly of a node-based vehicle. The fixtureless assembly system 500 may include one or more elements associated with at least a portion of assembling a vehicle in a fixtureless manner. For example, one or more elements of the fixtureless assembly system 500 may be configured for one or more operations in which a first structure is joined with one or more other structures without the use of any fixtures during robotic assembly of a node-based vehicle.

[0048] An assembly cell 505 may be configured at the location of the fixtureless assembly system 500. The assembly cell 505 may be a vertical assembly cell. Within the assembly cell 505, the fixtureless assembly system 500 may include a set of robots 507, 509, 511, 513, 515, 517. The robot 507 may be referred to as a "backbone robot." The fixtureless assembly system 500 may include part tables 520, 521, and 522 that may hold parts and structures for access by the robots. For example, a first structure 523, a second structure 525, and a third structure 527 may be placed on one of the part tables 521, 522 to be picked up by the robot and assembled together. In various embodiments, each of the structures may have a weight of at least 10 g, 100 g, 500 g, 1 kg, 5 kg, 10 kg, or more. In various embodiments, each of the structures can have a volume of at least 10 ml, 100 ml, 500 ml, 1000 ml, 5000 ml, 10000 ml, or more. In various embodiments, one or more of the structures can be additively manufactured structures, such as composite nodes.

[0049] The fixtureless assembly system 500 may also include a computing system 529 for issuing commands to various controllers of the robots in the assembly cell 505, as described in more detail below. In this example, the computing system 529 is communicatively coupled to the robots via wireless communication. The fixtureless assembly system 500 may also include a metrology system 531 that may precisely measure the position of the robot arms of the robots and / or the structure held by the robots, as described in more detail below.

[0050] In contrast to conventional robotic assembly factories, structures may be assembled without fixtures in the fixtureless assembly system 500. For example, structures do not need to be connected in any fixtures, such as the fixtures described above. Instead, at least one of the robots in the assembly cell 505 may provide the functionality expected from a fixture, as described in this disclosure. For example, the robots may be configured to directly contact (e.g., using end effectors of the robot arms) the structures to be assembled in the assembly cell 505, such that those structures may be engaged and held without the use of any fixtures. Additionally, at least one of the robots may provide the functionality expected from a positioner and / or fixture table. For example, the core robot 507 may replace the positioner and / or fixture table in the fixtureless assembly system 500.

[0051] The master robot 507 may include a base and a robotic arm (see, e.g., FIGS. 6B and 6C below). The robotic arm may be configured for movements that may be directed by computer-executable instructions loaded into a processor communicatively coupled to the master robot 507. The master robot 507 may contact a surface of the assembly cell 505 (e.g., the floor of the assembly cell) via the base.

[0052] The core robot 507 may include and / or be connected to an end effector configured to engage and hold a structure, e.g., a portion of a vehicle. An end effector may be a component configured to interface with at least one structure. Examples of end effectors may include jaws, grippers, pins, or other similar components that can facilitate fixtureless engagement and holding of a structure by the robot. In some embodiments, the structure may be a section of a vehicle chassis, body, frame, panel, base piece, etc. For example, the structure may be comprised of a floor panel.

[0053] In some embodiments, the master robot 507 may hold a connection with a structure via an end effector (e.g., a second structure 525 and end effector 543 shown in FIG. 6C and described in more detail below) while a set of other structures are connected (directly or indirectly) to the structure. The master robot 507 may be configured to engage and hold a structure without any fixtures. For example, none of the fixtures described above may be present in the fixtureless assembly system 500. In some embodiments, the structures to be held by at least one of the robots (e.g., a first structure) may be additively manufactured or co-printed with one or more features that facilitate engagement and holding of those structures by at least one of the robots without the use of any fixtures.

[0054] For example, the structure may be co-printed or additively manufactured with one or more features that increase the strength of the structure, such as a mesh, honeycomb, and / or lattice arrangement. Such features may stiffen the structure to prevent unintended movement of the structure during the assembly process. In another example, the structure may be co-printed or additively manufactured with one or more features that facilitate engagement and retention of the structure by an end effector, such as protrusions and / or recesses suitable for being engaged (e.g., "gripped") by an end effector. The aforementioned features of the structure may be co-printed with the structure and therefore may be of the same material as the structure.

[0055] In holding the structure, the core robot 507 may position (e.g., move) the structure, i.e., the position of the structure may be controlled by the core robot 507 when held by the core robot 507. The core robot 507 may hold the structure by, for example, "holding" or "grasping" the structure using an end effector of the core robot's robotic arm. For example, the core robot 507 may hold the structure by contacting one or more surfaces of the structure with gripper fingers, jaws, etc., and applying sufficient pressure thereto such that the core robot controls the position of the structure. That is, the structure may be prevented from moving freely in space when held by the core robot 507, and the movement of the structure may be constrained by the core robot. As discussed above, the structure may include one or more features that facilitate fixtureless engagement and holding of the structure by the core robot 507.

[0056] When another structure (including a subassembly, a substructure of a structure, etc.) is connected to the structure, the master robot 507 can maintain engagement with the structure via the end effector. The assembly of a structure and one or more structures connected thereto may be referred to as the structure itself, but may also be referred to as an "assembly" or a "subassembly." The master robot 507 may maintain engagement with the assembly after the master robot engages with the structure itself.

[0057] In some embodiments, robots 509 and 511 of assembly cell 505 may be similar to main robot 507 and therefore may include respective end effectors configured to engage structures that may be connected with structures held by the main robot. In some embodiments, robots 509, 511 may be referred to as "assembly robots" and / or "material handling robots."

[0058] In some embodiments, a robot 513 of the assembly cell 505 may be used to affect structural connections between structures. In the illustrative example of FIGS. 6A-6V, the robot 513 may be referred to as a "structural adhesive robot." The structural adhesive robot 513 may be similar to the backbone robot 507, except that the structural adhesive robot may include a tool at a distal end of the robot arm configured to apply structural adhesive to a surface of at least one of the structures fixturelessly held by the backbone robot and the structures fixturelessly held by the assembly robots 509, 511 before or after the structures are positioned in a joint proximity relative to the other structures for joining with the other structures. A joint proximity may be a location where a first structure may be joined to a second structure. For example, in various embodiments, the first and second structures may be joined via applying adhesive while the structures are in a joint proximity and then curing the adhesive.

[0059] However, the structural adhesive may take a relatively long time to cure. In this case, the robot holding the first and second structures may have to hold the structures in close proximity for a long time, for example, in order to be bonded by the structural adhesive after the structures have finally cured. This may prevent the robot from being used for other tasks (e.g., picking up and assembling the structures) for a long time while the adhesive cures. To allow the robot to be used more efficiently, for example, in various embodiments, a fast-curing adhesive may be additionally applied to quickly bond the structures and allow the structural adhesive to cure without the need for both robots to hold the structures.

[0060] In this regard, the robot 515 of the fixtureless assembly system 500 may be used to apply a fast-cure adhesive and quickly cure the adhesive. In this exemplary embodiment, a fast-cure UV adhesive may be used and the robot 515 may be referred to as a "UV robot." The UV robot 515 may be similar to the backbone robot 507, except that the UV robot may include a tool at a distal end of the robot arm configured to apply a fast-cure UV adhesive and cure the adhesive, for example, when a first structure is placed in joint proximity to a second structure. That is, the UV robot 515 may cure the adhesive after it is applied to the first structure and / or the second structure when the structures are in joint proximity obtained through at least one orientation of the robot arms of the backbone robot 507 and / or the assembly robots 509, 511.

[0061] In contrast to various other assembly systems that may include the positioners and / or fixture tables described above, the use of a curing bond (e.g., a fast-curing adhesive) may provide a partial adhesive bond that provides a way to hold the first and second structures during the bonding process without the use of fixtures. The partial adhesive bond may provide an alternative to various fixtures employed to engage and hold the structures, for example, in assembly systems that use positioners and / or fixture tables. Another potential advantage of fixtureless assembly, and particularly the use of a curing adhesive, is improved access to the various structures of a structural assembly, compared to the use of fixtures and / or other part holders that may inherently prevent access to the portions of the structure to which they are attached.

[0062] Additionally, at least partially replacing fixtures and / or other part-holding tools with the cured adhesive may provide a more reliable connection at one or more locations on the structural assembly requiring support, particularly where such locations requiring support are rendered largely or completely inaccessible by the fixtures and / or other part-holding equipment. Additionally, at least partially replacing fixtures and / or other part-holding tools with the cured adhesive may provide the ability to add additional structure to the structural assembly prior to application of the (permanent) structural adhesive, particularly where the fixtures and / or other part-holding tools obstruct access for joining additional structure.

[0063] In various embodiments, a robot may be used for multiple different roles. For example, robot 517 may perform the role of an assembly robot, such as assembly robots 509, 511, and the role of a UV robot, such as UV robot 515. In this regard, robot 517 may be referred to as an "assembly / UV robot." Assembly / UV robot 517 may provide similar functionality to each of assembly robots 509, 511 if the distal end of the robot arm of the assembly / UV robot includes an end effector (e.g., connected by a tool flange). However, assembly / UV robot 517 may provide similar functionality to UV robot 515 if the distal end of the robot arm of the assembly / UV robot includes a tool configured to apply UV adhesive and radiate ultraviolet light to cure the UV adhesive.

[0064] The fast-curing adhesive applied by UV robot 515 and assembly / UV robot 517 may provide a partial adhesive bond in that the adhesive may hold the relative positions of the first structure and the second structure within bonding proximity until a structural adhesive can be applied and / or cured to permanently bond the first structure and the second structure, after which the adhesive providing the partial adhesive bond may be removed (e.g., like a temporary adhesive) or may not be removed (e.g., like a complementary adhesive).

[0065] In the fixtureless assembly system 500, at least one surface of the first structure and / or second structure to which adhesive should be applied may be determined based on gravity and / or other forces causing loads on various structures and / or connections of the assembly. Finite element method (FEM) analysis may be applied to determine at least one surface of the first structure and / or second structure to which adhesive should be applied and one or more discrete areas on the at least one surface. For example, the FEM analysis may indicate one or more connections of the structural assembly that are unlikely or may not be able to support a section of the structural assembly located about the one or more connections.

[0066] During assembly of at least a portion of a vehicle in the assembly cell 505, a second structure may be directly bonded to a first structure by directing various fixtureless robots 507, 509, 511, 513, 515, 517 as described herein. Additional structures may be indirectly bonded to a first structure. For example, a first structure may be directly bonded to a second structure via the movement(s) of the backbone robot 507, the structural adhesive robot 513, at least one assembly robot 509, 511, and / or the UV robot 515. The first structure bonded to the second structure may then be indirectly bonded to the additional structure by the additional structure being bonded directly to the second structure. Thus, the first structure, which may continue to be held by the backbone robot 507, may evolve through the assembly process as additional structures are bonded directly or indirectly.

[0067] In some embodiments, the assembly robots 509, 511 may fixturelessly bond two or more structures together, for example with a partial fast-cure adhesive bond, and then fixturelessly bond the two or more structures to a first structure held by the backbone robot 507. Two or more structures that are bonded together before being bonded in a structural assembly may also be structures and may further be referred to as a "subassembly." Thus, if a structure forms part of a structural subassembly that is connected to a first structure through the movements of the backbone robot 507, the structural adhesive robot 513, at least one assembly robot 509, 511, and the UV robot 515, a structure of the structural subassembly may be indirectly connected to the first structure when the structural subassembly is bonded to a structural assembly that includes the first structure.

[0068] In some embodiments, the structural adhesive may be applied, such as by depositing it in a groove of one of the structures, before the first and second structures are brought into the joint vicinity. For example, the structural adhesive robot 513 may include a dispenser for the structural adhesive and may apply the structural adhesive before the structures are brought into the joint vicinity. In some embodiments, the structural adhesive may be applied after the structural assembly is fully assembled, such as when each structure of the vehicle portion is brought into the respective joint vicinity and secured to the joint vicinity by application of a fast-curing UV adhesive. For example, the structural adhesive may be applied to one or more joints or other connections between the first structure and the second structure. The structural adhesive may be applied at a time after the final adhesive cure by the UV robot 515 has occurred. In some embodiments, the structural adhesive may be applied separately from the fixtureless assembly system 500.

[0069] After the assembly is complete, i.e., all of the structures are assembled and held together in a partial adhesive bond, e.g., with the application of a fast-curing UV adhesive, and the structural adhesive applied, the structural adhesive may be cured. Upon curing the structural adhesive, the vehicle portion may be completed and therefore suitable for use in a vehicle. For example, the completed structural assembly may meet any applicable industry and / or safety standards defined for consumer and / or commercial vehicles. In some embodiments, the adhesive applied by the UV robot 515 to achieve the partial adhesive bond to hold the structures may be removed, e.g., after the structural adhesive has cured. In some embodiments, the adhesive for the partial adhesive bond may remain attached to the structure.

[0070] According to various embodiments, one or more of the robots 507, 509, 511, 513, 515, 517 may be secured to a surface of the assembly cell 505 via a respective base of the respective robot. For example, one or more of the robots may have a base that is bolted to the floor of the assembly cell. In various other embodiments, one or more of the robots may include or be connected to a component configured to move the robot within the assembly cell 505. For example, a carrier 519 within the assembly cell 505 may be connected to the assembly / UV robot 517.

[0071] 6-6V, which illustrate various configurations of robots 507, 509, 511, 513, 515, 517 during various operations of the fixtureless assembly system 500. Figures 6A-6V illustrate exemplary fixtureless joining operations according to various embodiments.

[0072] An exemplary control system will be described first. Each of the robots 507, 509, 511, 513, 515, 517 may be communicatively connected to a controller, such as a respective one of the controllers 607, 609, 611, 613, 615, 617 shown in Figures 5 and 6A-6V. Each of the controllers 607, 609, 611, 613, 615, 617 may include, for example, a memory and a processor communicatively connected to the memory (e.g., as described with respect to Figure 10 below). According to some other embodiments, one or more of the controllers 607, 609, 611, 613, 615, 617 may be implemented as a single controller communicatively connected to one or more of the robots controlled by the single controller.

[0073] Computer readable instructions for performing fixtureless assembly may be stored on the memory of the controllers 607, 609, 611, 613, 615, 617, and the processors of the controllers can execute the instructions to cause the robots 507, 509, 511, 513, 515, 517 to perform various fixtureless operations such as those described with respect to Figures 6A-6V.

[0074] The controllers 607, 609, 611, 613, 615, 617 may be communicatively coupled to one or more components of the associated robot 507, 509, 511, 513, 515 or 517, for example, via wired (e.g., a bus or other interconnect) and / or wireless (e.g., wireless local area network, wireless intranet) connections. Each of the controllers can issue commands, requests, etc. to one or more components of the associated robot, for example to perform various fixtureless operations.

[0075] According to some embodiments, the controller 607, 609, 611, 613, 615, 617 may issue commands to the robot arm of the associated robot 507, 509, 511, 513, 515, or 517, for example, directing the robot arm based on a set of absolute coordinates relative to the global cell reference frame of the assembly cell 505. In various embodiments, the controller 607, 609, 611, 613, 615, 617 may issue commands to a tool connected to a distal end of the robot arm. For example, the controller may control the operation of the tool, including depositing a controlled amount of adhesive on a surface of a first structure or a second structure by an adhesive applicator, exposing the adhesive deposited between the structures to UV light for a controlled amount of time by a curing tool, etc. In various embodiments, the controller 607, 609, 611, 613, 615, 617 may issue commands to an end effector at the distal end of the robot arm. For example, the controller may control the operation of the end effector, including engaging, holding, and / or manipulating a structure.

[0076] According to various other aspects, a computing system, such as computing system 529, also having a processor and memory, may be communicatively coupled to one or more of controllers 607, 609, 611, 613, 615, 617. In various embodiments, the computing system may be communicatively coupled to the controller via a wired and / or wireless connection, such as a local area network, an intranet, a wide area network, etc. In some embodiments, the computing system may be implemented in one or more of controllers 607, 609, 611, 613, 615, 617. In some other embodiments, the computing system may be located outside of assembly cell 505. An example of such a computing system is described below with respect to FIG. 10.

[0077] The processor of the computing system may execute instructions loaded from memory, which execution may cause the computing system to issue commands, etc. to the controllers 607, 609, 611, 613, 615, 617, such as by sending a message containing the command, etc., to one of the controllers over a network connection or other communications link.

[0078] According to some embodiments, one or more of the commands may indicate a set of coordinates and indicate an action to be performed by one of the robots 507, 509, 511, 513, 515, 517 associated with one of the controllers that received the command. Examples of actions that may be indicated by a command include directing the movement of a robot arm, manipulating a tool, engaging a structure with an end effector, rotating and / or translating a structure, etc. For example, a command issued by a computing system may cause a controller 609 of the assembly robot 509 to direct the robot arm of the assembly robot 509 such that a distal end of the robot arm may be positioned based on a set of coordinates indicated by the command.

[0079] The instructions that are loaded from memory and executed by the processor of the computing system to cause the controller to control the operation of the robot may be based on computer-aided design (CAD) data. For example, a CAD model of the assembly cell 505 (e.g., including a CAD model of a physical robot) may be constructed and used to generate commands issued by the computing system.

[0080] In some embodiments, one or more CAD models may represent locations corresponding to various elements within the assembly cell 505. Specifically, the CAD models may represent locations corresponding to one or more of the robots 507, 509, 511, 513, 515, 517. Additionally, the CAD models may represent locations corresponding to structures and repositories of structures (e.g., storage elements such as parts tables within the fixtureless assembly system 500 where structures may be placed prior to being engaged by an assembly robot). In various embodiments, the CAD models may represent sets of coordinates corresponding to initial or base positions for each of the robots 507, 509, 511, 513, 515, 517, respectively.

[0081] For such CAD modeling, a reference frame for a coordinate system may be defined. The coordinate system may include absolute coordinates, relative coordinates, or a combination thereof. For a set of absolute coordinates, the coordinate frame may be a global coordinate frame or a global cell reference frame, and the coordinate frame may include (e.g., may be bounded by and / or defined by) the assembly cell 505.

[0082] The coordinate frame may be established based on one or more ground datums (e.g., one or more laser prisms) within the assembly cell 505, and each of the laser prisms may be measured within the assembly cell such that a reference frame is defined having a number of datum points corresponding to the number of laser prisms in the assembly. Thus, the CAD model corresponding to the assembly cell 505 may be an as-built CAD model, which may more accurately represent the assembly cell than a nominal CAD model. Absolute coordinates based on CAD modeling may provide an acceptable degree of accuracy for fixtureless assembly of the vehicle. For example, directing the robots 507, 509, 511, 513, 515, 517 based on absolute coordinates established through CAD modeling may comply with various industry and / or safety standards that should be adhered to when assembling a vehicle.

[0083] In various embodiments, relative coordinates may be used in the fixtureless assembly system 500, for example, as an alternative or supplement to an absolute coordinate system. In particular, relative coordinates may be used for some portions of a fixtureless joining process in which a second structure may be joined to a first structure and / or joined to another structure. For example, a controller associated with an assembly robot may direct a robot arm of the assembly robot to a joining location based on a set of absolute coordinates defined with respect to a global cell reference frame. The position of the robot arm may be measured (e.g., by a controller of the assembly robot, by a controller of the mission robot, by another controller and / or processing system, etc.) after the assembly robot reaches the joining location based on the set of absolute coordinates, and the measured position of the assembly robot may be provided to a controller of the mission robot. The controller of the mission robot may position the robot arm of the mission robot based on the measured position of the robot arm of the assembly robot. Thus, the arm of the master robot may be positioned relative to the arm of the assembly robot, for example, instead of correcting the respective positions of the master robot and the assembly robot according to a global cell reference frame, while the controller may remain agnostic to the positions of the master robot or the assembly robot.

[0084] Further, the CAD model may represent one or more operations to be performed in the assembly cell 505 to build at least a portion of a vehicle. In other words, the CAD model may simulate an assembly procedure of the fixtureless assembly system 500, and thus each of the movements and / or actions performed by one or more robots. The CAD simulation may be translated into a set of discrete operations (e.g., a discrete operation may include an orientation relative to a set of associated coordinates), which may be physically performed by one or more robots.

[0085] To illustrate, the movements of the assembly robot and the structural adhesive robot within the reference frame of the assembly cell 505 may be simulated to model absolute coordinates (and optionally time) for the operations of the assembly robot and the structural adhesive robot. For example, the CAD model may simulate three operations: (1) a first time and a first set of coordinates for fixtureless engagement of a structure placed on a parts table by an end effector of the assembly robot, (2) a second time and a second set of coordinates for directing the assembly robot to position the structure proximate to the structural adhesive robot for application of adhesive, and (3) a third time and a third set of coordinates for directing the structural adhesive robot to apply adhesive to a surface of the structure. The exemplary simulated operations may then be converted into one or more sets of discrete instructions, which may be loaded into the memory of one or more controllers communicatively connected to the assembly robot and the structural adhesive robot. When executed by a processor of the respective controller, the sets of discrete instructions may cause the robots of the fixtureless assembly system 500 to perform the operations simulated through the CAD model.

[0086] Each of the robots 507, 509, 511, 513, 515, 517 may include features common to all or a portion of the robots. For example, all of the robots may include a base, each of which has a surface (e.g., a bottom surface) that contacts the assembly cell 505 (e.g., rests on or is fixed to the floor of the assembly cell). Each base may have another surface (e.g., a top surface and / or a surface disposed on the base opposite the surface that contacts the assembly cell 505) at which the base may be connected to a proximal end of each robot arm of each of the robots.

[0087] In some embodiments, the base may be connected to a proximal end of the robotic arm via at least one rotational and / or translational mechanism. The at least one rotational and / or translational mechanism may provide at least one degree of freedom for movement of an end effector or other tool of the robotic arm. Correspondingly, the at least one rotational and / or translational mechanism may provide at least one degree of freedom for movement of a structure engaged and held by the end effector or other tool of the robotic arm.

[0088] Each robot arm of the robots 507, 509, 511, 513, 515, 517 may include a distal end disposed opposite from the proximal end of the robot arm. As described herein (e.g., with respect to Figures 6A-6V below), each robot arm of each of the robots may include an end effector and / or tool, such as an adhesive application tool, a curing tool, etc. The end effector or tool may be present at the distal end of the robot arm. In some embodiments, the distal end of the robot arm may be connected to the end effector or tool (or tool flange) via at least one rotational and / or translational mechanism, which may provide at least one degree of freedom for movement of the tool and / or movement of a structure engaged and held by the tool of the robot arm.

[0089] In some embodiments, the distal end of the robot arm may include a tool flange and a tool included in the tool flange, e.g., the tool may be connected to the distal end of the robot arm by the tool flange. The tool flange may be configured to include multiple tools. In this manner, for example, the assembly / UV robot 517 may provide functionality similar to each of the assembly robots 509, 511 if the distal end of the robot arm of the assembly / UV robot 517 includes an end effector (e.g., connected by a tool flange). Furthermore, the assembly / UV robot 517 may provide functionality similar to the UV robot 515 if the distal end of the robot arm of the assembly / UV robot 517 includes a tool configured to apply UV adhesive and emit UV light to cure the adhesive.

[0090] According to some embodiments, the tool flange and / or tool may provide one or more additional degrees of freedom for rotation and / or translation of a structure engaged and held by the tool. Such additional degrees of freedom may supplement one or more degrees of freedom provided via one or more mechanisms connecting the base to the proximal end of the robot arm and / or connecting the distal end of the robot arm to the tool (or tool flange). Illustratively, at least one robot arm of the robots 507, 509, 511, 513, 515, 517 may include at least one joint configured to rotate and / or translate at the distal and / or proximal end, such as an articulated joint, a ball joint, and / or other similar joint.

[0091] Each of the connections (e.g., one or more rotational and / or translational mechanisms connecting various components of one of the robots), each tool flange, and / or each tool of the robots 507, 509, 511, 513, 515, 517 may provide at least a portion (and potentially all) of six degrees of freedom (6DoF) to a structure engaged and held by the robot. The 6DoF may include forward / backward (e.g., surge), up / down (e.g., heave), left / right (e.g., sway) for translation in space, and may further include yaw, pitch, and roll for rotation in space. In contrast to holding a structure with a fixture that cannot provide 6DoF in the movement of the structure and blocks access to critical parts of the structure attached to it, access to various parts of the structure may be achievable through one or more of the 6DoF.

[0092] In an assembly system that includes fixtures, positioners, and / or fixture tables, 6DoF may not be achievable during the assembly process because, for example, at least one of the fixtures, positioners, and / or fixture tables may prevent one or more of surge, heave, sway, yaw, pitch, and / or roll of the structure to which the fixtures are attached. Inability to achieve 6DoF, coupled with a reduction in available space commensurate with the use of fixtures, positioners, and / or fixture tables for accessing and / or manipulating the structure, may render some critical parts of the structure inaccessible.

[0093] Inaccessibility of portions of a structure can make the vehicle assembly process difficult, for example, inaccessibility of a surface of a structure to which another structure is to be joined can render the structural assembly unsuitable for use in a vehicle that must meet various industry and / or safety standards for commercial and / or consumer vehicles.

[0094] In contrast, fixtureless robotic manipulation for building structural assemblies as described herein (e.g., with respect to fixtureless assembly system 500) may feature more degrees of freedom (e.g., all 6 DoF) than assembly systems that rely on fixtures, positioners, and / or fixture tables. Accordingly, fixtureless robotic manipulation (e.g., fixtureless assembly system 500) may reduce the complexities and / or difficulties inherent in the manipulation and / or accessibility of structures in particular, thereby increasing the likelihood that structural assemblies obtained through fixtureless assembly system 500 may meet various industry and / or safety standards.

[0095] Exemplary operations of the fixtureless assembly system 500 will now be described in Figures 6A-6V. As described herein, the exemplary operations may be triggered by at least one of the controllers 607, 609, 611, 613, 615, 617 communicatively coupled to the robots 507, 509, 511, 513, 515, 517. In some embodiments, the computing system 529 may issue commands to the controllers 607, 609, 611, 613, 615, 617 to trigger the exemplary operations. The computing system 529 and / or the controllers 607, 609, 611, 613, 615, 617 may trigger the exemplary operations based on CAD data that may model a physical robot performing the exemplary operations and / or position data that may be provided by a metrology system 531.

[0096] For the exemplary operation of the fixtureless assembly system 500, the robots 507, 509, 511, 513, 515, 517 may be positioned relatively close to one another, e.g., at a distance suitable for the exemplary operation described below. In some embodiments, one or more of the robots 507, 509, 511, 513, 515, 517 may be positioned in the fixtureless assembly system 500 prior to the exemplary operation described below, at a location suitable for the one or more exemplary operations. At such a location, the base of each of those one or more robots may be stationary throughout the exemplary operation of the fixtureless assembly system 500. However, the movements of the robot arms of the robots 507, 509, 511, 513, 515, 517 may be coordinated and controlled at various stages of the fixtureless assembly system 500, such as rotating, hinged, and / or otherwise articulating about their respective bases.

[0097] In some other embodiments, the different robots 507, 509, 511, 513, 515, 517 may be dynamically (re)positioned at different distances from one another at different stages of the fixtureless assembly. The carrier 519 may be configured to move the one or more robots 507, 509, 511, 513, 515, 517 to their respective positions, for example, according to execution by one or more processors of one or more sets of instructions related to fixtureless assembly. The respective locations at which each of the robots 507, 509, 511, 513, 515, 517 is positioned, whether static or dynamic, may be based on one or more sets of coordinates (e.g., one or more sets of absolute coordinates) related to the fixtureless assembly system 500.

[0098] 6A , an assembly robot 511 can engage a first structure 523. The first structure 523 can include one or more features that enable mating of the first structure 523 with one or more other structures. Illustratively, the first structure 523 can include a groove 533 on a first surface and a tongue 535 on a second surface. The first surface and the second surface of the first structure 523 can be on different sides of the first structure (e.g., the first surface can be on a left or top side of the first structure 523 and the second surface can be on a right or bottom side of the first structure 523, or vice versa).

[0099] The assembly robot 511 may be positioned relatively close to the parts table 521. In such a location, the robot arm of the assembly robot 511 may be in proximity where the robot arm of the assembly robot 511 can reach at least a portion of the parts positioned on the parts table 521. In the exemplary embodiment of FIG. 6A , the assembly robot 511 may be located to one side of the parts table 521, and the groove 533 of the first structure 523 may be relatively closer to the assembly robot 511 than the tongue 535 of the first structure 523 at such a location of the assembly robot 511.

[0100] The assembly robot 511 may be connected to an end effector 537. Illustratively, a distal end of a robot arm of the assembly robot 511 may be connected to the end effector 537, which may be built on the distal end of the robot arm or may be attached to the robot arm (and may be fixed or removable). The end effector 537 of the assembly robot 511 may be configured to engage (e.g., "pick up") and hold one or more structures. For example, the end effector 537 of the assembly robot 511 may be configured to engage different structures, such as via one or more features of the different structures. Some examples of such end effectors may include jaws or grippers.

[0101] The assembly robot 511 may engage the first structure 523, for example, at approximately a side of the first structure that does not have the groove 533 or tongue 535. Specifically, the robot arm of the assembly robot 511 may move to a position where an end effector 537 of the assembly robot 511 can engage the first structure 523. At this position, the end effector 537 of the assembly robot 511 engages the first structure 523, for example, at a different side and / or surface than the groove 533 or tongue 535. Once engaged, the assembly robot 511 may hold the first structure 523, for example, by the end effector 537. Once the first structure 523 is held by the assembly robot 511, the assembly robot 511 may move the first structure 523 to one or more positions where one or more example operations of fixtureless assembly may be performed, as described further below.

[0102] 6B, assembly robot 511 may pivot to face structural adhesive robot 513. The distal end of the robot arm of assembly robot 511 may be positioned toward structural adhesive robot 513, and similarly, the distal end of the robot arm of structural adhesive robot 513 may be positioned toward assembly robot 511.

[0103] 6B, the assembly robot 511 may move the first structure 523 to a position where the first structure is approximately between the assembly robot 511 and the structural adhesive robot 513. Additionally, the assembly robot 511 may orient the first structure 523 so that the groove 533 is approximately facing upward, such as by moving a robot arm of the assembly robot 511 and / or an end effector 537 of the assembly robot 511 such that the first structure 523 is oriented approximately upward.

[0104] Structural adhesive robot 513 may be connected to a structural adhesive applicator 539 or other similar tool. Illustratively, structural adhesive applicator 539 may be integrated into a distal end of a robot arm or may be attached (and may be fixed or removable) to the robot arm. Structural adhesive applicator 539 may be configured to deposit adhesive onto a structural surface.

[0105] Once the first structure 523 is suitably positioned (e.g., between the two robots 511, 513), the structural adhesive robot 513 may cause the application of adhesive to the first structure 523. Specifically, the structural adhesive robot 513 may deposit adhesive into the groove 533 of the first structure 523. To do so, the structural adhesive robot 513 may move its robot arm to a position where the structural adhesive applicator 539 is above the groove 533 and close enough so that a controlled amount of adhesive may be deposited within a defined area while avoiding the deposition of adhesive on unintended surfaces. In such said position, the adhesive application tip of the structural adhesive applicator 539 may be approximately directly above the groove 533 and pointed downward into the groove 533.

[0106] Once deposited, the controlled amount of adhesive may at least partially fill groove 533. In some embodiments, the controlled amount of adhesive may completely or nearly completely fill groove 533. However, the amount of adhesive may be controlled such that the adhesive does not overflow outside groove 533 and onto a first surface of first structure 523 that borders groove 533. For example, the amount of adhesive deposited in groove 533 may be controlled such that the adhesive does not leak onto any surface of first structure 523 when first structure 523 is joined to another structure when a protrusion, such as a tongue, of the other structure is inserted into groove 533.

[0107] 6C, the master robot 507 can engage a second structure 525. Similar to the first structure 523, the second structure 525 can include one or more features that enable the second structure 525 to interface with one or more other structures. In the illustrated embodiment, the second structure 525 can include a groove 547 on a first surface and a tongue 545 on a second surface. The first and second surfaces of the second structure 525 can be generally opposite one another.

[0108] The second structure 525 may be located on the part table 522 and the resource robot 507 may be located relatively close to the part table 522. In such a location, the robot arm of the resource robot 507 may be in close proximity where the robot arm of the resource robot 507 can reach at least a portion of a part located on the part table 522. In the exemplary embodiment of FIG. 6C, the resource robot 507 may be located on one side of the part table 522 and the tongue 545 of the second structure 525 may be positioned toward a side of the part table 522 that is relatively opposite to the side on which the resource robot 507 is located. In this position, the groove 547 of the second structure 525 faces toward the resource robot 507.

[0109] The master robot 507 may be connected to an end effector 543. Illustratively, a distal end of a robot arm of the master robot 507 may be connected to the end effector 543, which may be built on the distal end of the robot arm or may be attached to the robot arm (and may be fixed or removable). The end effector 543 of the master robot 507 may be configured to engage (e.g., "pick up") and hold one or more structures. For example, the end effector 543 of the master robot 507 may be configured for fixtureless engagement with different structures, such as via one or more features of the different structures. Some examples of such end effectors may include jaws or grippers.

[0110] The master robot 507 can engage the second structure 525 at a first surface, i.e., the surface where the groove 547 is located. Specifically, the robot arm of the master robot 507 can be moved to a position where the master robot can engage the second structure 525, and the master robot 507 can then engage and hold the second structure 525 at the first surface using the end effector 543.

[0111] 6D , the core robot 507 may be pivoted to face the assembly robot 511, and the assembly robot may be pivoted to face the core robot. The distal end of the robot arm of the core robot 507 may be positioned toward the assembly robot 511, and similarly, the distal end of the robot arm of the assembly robot 511 may be positioned toward the core robot 507.

[0112] 6D, the master robot 507 may move the second structure 525 to a position where the second structure 525 is approximately between the master robot 507 and the assembly robot 511. Additionally, the master robot 507 may orient the second structure 525 so that a tongue 545 of the second structure 525 is approximately pointing downward, such as by moving a robot arm of the master robot 507 and / or an end effector 543 of the master robot 507 so that the second structure 525 is oriented approximately downward.

[0113] In some embodiments, the master robot 507 may move the second structure 525 according to one or more vectors, which may be based on CAD modeling. Each of the one or more vectors may indicate a magnitude (e.g., distance) and direction according to which the second structure 525 is to be moved by the master robot 507. Each vector may be intended to direct the second structure 525 into the joint vicinity, while some vectors may be intermediate vectors intended to direct the second structure 525 to a position where vectors for joining the first and second structures 523, 525 are applicable.

[0114] The assembly robot 511 may position the first structure 523 relatively closer to the assembly robot 511 than to the backbone robot 507. In some embodiments, the assembly robot 511 may position the first structure 523 to be at least partially above at least a portion of the second structure 525. For example, the assembly robot 511 may hold the first structure 523 in a generally overhead position.

[0115] 6E, the assembly robot 511 and the main robot 507 may move the first structure 523 and the second structure 525, respectively, to positions close to each other, but not close enough to join. Additionally, the first structure 523 may be positioned to be below the second structure 525, for example, such that the first structure 523 and the second structure 525 at least partially overlap in the elevation plane (or vertical space).

[0116] The assembly robot 511 may orient the first structure 523 such that the groove 533 of the first structure 523 faces generally upward and has a controlled amount of adhesive pre-deposited therein. For example, the assembly robot 511 may move its robot arm and / or end effector 537 such that the groove 533 of the first structure 523 is oriented generally upward. Thus, the groove 533 of the first structure 523 may face the tongue 545 of the second structure 525.

[0117] Similar to the movement of the second structure 525 by the backbone robot 507, the assembly robot 511 may move the first structure 523 according to one or more vectors, which may be based on CAD modeling. Each of the one or more vectors may indicate a magnitude (e.g., distance) and direction according to which the first structure 523 is to be moved by the assembly robot 511. Each vector may be intended to direct the first structure 523 into a joint vicinity, while some vectors may be intermediate vectors intended to direct the first structure 523 to a position where vectors for joining the first and second structures 523, 525 are applicable.

[0118] The backbone robot 507 may hold the second structure 525 in the position previously described with the tongue 545 oriented generally downward, but the second structure 525 may now be disposed above the first structure 523 due to the movement of the first structure 523 caused by the assembly robot 511. However, the first and second structures 523, 525 may not yet be within a joint vicinity where the first structure may be joined with the second structure.

[0119] 6F illustrates how the first structure 523 and the second structure 525 may be brought into a joint vicinity where the two structures may be joined. To bring the first and second structures 523, 525 into a joint vicinity, one or both of the first and / or second structures may be moved by one or both of the assembly robot 511 and / or the master robot 507, respectively. For example, the assembly robot 511 may move a distal end of its robot arm, to which the first structure 523 is engaged, in a generally upward direction toward the second structure 525. Additionally or alternatively, the master robot 507 may move a distal end of its robot arm, to which the second structure 525 is engaged, in a generally downward direction toward the first structure 523.

[0120] In various embodiments, joining of structures engaged by a robot in the fixtureless assembly system 500 may be accomplished using a "move-measure-fix" procedure. In effect, the move-measure-fix procedure may include moving at least one structure toward a joint vicinity, measuring at least one difference between a current position of one of the structures (e.g., the physical location of the structure) and a position where the structure may be joined (e.g., the joint vicinity), and correcting the position of at least one of the structures so that the structure may be brought into the joint vicinity, at which point the structure may be joined. The move-measure-fix procedure may be repeated for one or more of the structures to be joined until the structure is brought into the joint vicinity, at which point the joining operation may be accomplished such that the structures are joined (e.g., within tolerances). It is possible that the structures can be brought into the joint vicinity in one step, and therefore repeating the procedure may not be necessary in all cases.

[0121] The move-measure-fix procedure may use metrology system 531, which may be configured to determine (e.g., detect, calculate, measure, capture, etc.) position data associated with assembly cell 505. The position data may include a set of measurements or other values ​​indicative of one or more positions of the structure and / or robot (e.g., including the robot arm and / or components connected with the robot, such as tools, flanges, end effectors, etc.). Metrology system 531 may include one or more devices disposed within and / or proximate to assembly cell 505, and may include, for example, a tracker machine control sensor (T-MAC), a laser metrology device (e.g., configured for laser scanning and / or tracking), a photogrammetry device, a camera (e.g., configured to take still images and / or video), and / or another device similarly configured to determine position data.

[0122] In some embodiments, the metrology system 531 may determine the position data based on at least one target within the assembly cell 505, which may be located on the robot (e.g., including a robot arm and / or components connected with the robot, such as a tool, a flange, an end effector, etc.), one or more of the structures to be joined, and / or elsewhere within the assembly cell 505. The at least one target may be detectable / identifiable by the metrology system 531 within the assembly cell 505. For example, the at least one target may be reflective and / or have a particular shape to distinguish the at least one target within the assembly cell 505.

[0123] The metrology system 531 may provide position data to the computing system 529. For example, the position data may indicate a set of coordinates associated with the structure. The set of coordinates may include at least one of a set of absolute coordinates (e.g., in the global coordinate frame of the assembly cell 505) and / or a set of relative coordinates (e.g., relative to a joint vicinity and / or relative to another one of the structures).

[0124] The position data may be used by the computing system 529 to determine (e.g., measure or calculate) a difference between a current position of one of the structures and the joint vicinity. For example, the computing system 529 may determine a difference between a set of coordinates indicated by the position data and set coordinates or expected coordinates, which may be coordinates where the structure is expected to be located to be brought into the joint vicinity.

[0125] If necessary, the position of at least one of the structures may be modified based on the determined difference. For example, imperfections and / or other inaccuracies in the robots in the fixtureless assembly system 500 may cause the structures to drift or otherwise become out of alignment with the joint vicinity and / or the vectors or coordinates to which the structure should be moved so that it can be brought into the joint vicinity. If the determined difference is not within the tolerance of the joint vicinity, the computing system 529 may determine a set of vectors and / or coordinates to which one of the structures should be moved so that the structure can be brought into the joint vicinity.

[0126] The computing system 529 may then issue a command to one of the controllers 607, 609, 611, 613, 615, 617 communicatively coupled to one of the robots 507, 509, 511, 513, 515, 517 holding the structure, causing the controller to modify the position of the structure such that the structure is brought into the joint vicinity. For example, one of the robots 507, 509, 511, 513, 515, 517 may move the structure according to a vector and / or set of coordinates determined based on the issued command.

[0127] 6F , metrology system 531 may determine position data associated with at least one of first structure 523 and / or second structure 525 within assembly cell 505. For example, metrology system 531 may determine a set of coordinates associated with first structure 523. The set of coordinates may indicate a physical location of first structure 523 within assembly cell 505 and / or a relative location with respect to a joint vicinity or second structure 525.

[0128] The metrology system 531 may provide the position data to the computing system 529. The computing system 529 may receive the position data and, based on the position data, may determine a set of corrective operations to apply to bring the first structure 523 into the junction vicinity so that it can mate with the second structure 525. For example, the computing system 529 may determine a difference between a set of coordinates associated with the first structure 523 and the junction vicinity.

[0129] Based on the determined difference, the computing system 529 may determine a set of corrective operations to be applied to the first structure 523 so that the first structure 523 may be brought into joint proximity. In some embodiments, the set of corrective operations may include a set of vectors, each of which indicates a magnitude and a direction in which the first structure 523 may be moved into the joint proximity. In some other embodiments, the set of corrective operations may include a set of coordinates associated with directing the first structure 523 into the joint proximity, such as a set of coordinates to which a robot arm of the assembly robot 511 should be controlled so that the first structure 523 is brought into joint proximity.

[0130] The computing system 529 may provide the set of corrective operations to a controller 611 communicatively coupled to the assembly robot 511, such as by issuing a set of commands to the controller 611. The controller 611 may apply the set of commands by controlling a robotic arm of the assembly robot 511 according to the set of corrective operations indicated by the set of commands.

[0131] In some embodiments, the metrology system 531 may again determine position data associated with at least one of the first structure 523 and / or the second structure 525 after the aforementioned set of corrective operations have been applied. The computing system 529 may receive the subsequent position data and may determine a next set of corrective operations, if necessary, to bring the first structure 523 and the second structure 525 into the joint vicinity based on the subsequent position data. If a next set of corrective operations is necessary, the computing system 529 may issue a next set of commands to one of the controller 607 or the controller 611 (e.g., depending on whether the first structure 523 or the second structure 525 is moved). The controller receiving the next set of commands may control the corresponding one of the mission robot 507 or the assembly robot 511 according to the next set of corrective operations. The move-measure-correct procedure may be repeated iteratively until the computing system 529 determines that the first structure 523 and the second structure 525 are in the joint vicinity and no further corrective operations should be applied. Thus, first structure 523 and second structure 525 may be joined at a joint vicinity.

[0132] When the structures are in mating proximity, at least a portion of one structure overlaps at least a portion of another structure in at least one of the azimuth (or horizontal) and / or elevation planes. Such overlap allows one or more features of one structure to connect with one or more complementary features of another structure by interlocking or mating, such as when a protrusion of one structure is inserted into a recess of another structure. In operation of the illustrated example of the fixtureless assembly system 500, when the first structure 523 and the second structure 525 are in mating proximity, the tongue 545 of the second structure 525 may be placed into the groove 533 of the first structure 523, thereby forming a tongue and groove joint.

[0133] In some embodiments, the tongue 545 of the second structure 525 may not contact the first structure 523 in the joint vicinity. In other words, the robot may be controlled to guide the structure into the joint vicinity while preventing the structures from contacting each other. For example, the tongue 545 of the second structure 525 may be in the groove 533 of the first structure 523, but lateral bond gaps such as lateral bond gaps 561a, 561b (collectively lateral bond gaps 561 herein) between the tongue and the sides of the groove and vertical bond gaps 562 between the tongue and the bottom of the groove may occur because the tongue is inserted into the groove without contacting the sides and bottom. Rather, the tongue 545 of the second structure 525 may simply contact the structural adhesive deposited in the groove 533 of the first structure 523 (as shown above in FIG. 6B) when the first structure 523 and the second structure 525 are in the joint vicinity. However, in some further embodiments, the surface surrounding groove 533 of first structure 523 may contact the surface surrounding tongue 545 of second structure 525 .

[0134] The bond gap resulting from non-contact bonding can provide a significant advantage when assembling multi-part structures. Specifically, for each individual bonding operation, there may be spatial errors that may be due to, for example, improper positioning of the structure, dimensional variations of the structure (e.g., a 3D printed structure may not have the exact dimensions expected due to the nature of 3D printing), etc. In a typical bonding operation, these errors may accumulate each time a multi-part structure is bonded, resulting in a large dimensional error in the final assembly. However, the bond gap resulting from non-contact bonding can absorb the dimensional errors of the individual bonds. The bond shown in FIG. 6O provides more details on how the bond gap can absorb dimensional errors.

[0135] 6G, the master robot 507 and the assembly robot 511 can remain in their respective positions such that the second structure 525 and the first structure 523 are in joint proximity.

[0136] With such positioning maintained, the UV robot 515 may be positioned relatively close to the core robot 507 and the assembly robot 511. The distal end of the robot arm of the UV robot 515 may be positioned toward the first structure 523 and the second structure 525, specifically toward the point where the first structure 523 and the second structure 525 are joined (e.g., toward the tongue-and-groove junction). In such a position, the distal end of the robot arm of the UV robot 515 may be between the core robot 507 and the assembly robot 511.

[0137] The UV robot 515 may be connected to a tool 549, which may be specifically connected to a distal end of a robot arm of the UV robot 515. The tool 549 may be configured to bond the first structure 523 and the second structure 525 at a joint vicinity. For example, the tool 549 may be configured with or connected to one or more applicators, such as applicators 575, 577, to apply a UV or other temporary adhesive (e.g., via the UV adhesive applicator 575) and emit UV light (e.g., via the UV light applicator 577) or otherwise cure the UV or other temporary adhesive, thereby bonding the first structure 523 and the second structure 525. The bond created by the UV robot 515 may be temporary, while the structural adhesive (applied by the structural adhesive robot 513, as described above in FIG. 6B) may provide a permanent bond when cured.

[0138] The distal end of the robot arm of the UV robot 515 may be positioned such that a tool 549 connected to the UV robot 515 is proximate to a point of adjoining the first structure 523 and the second structure 525. For example, the robot arm of the UV robot 515 may be positioned such that the tool 549 is positioned a distance from the tongue-and-groove junction (formed by positioning the first structure 523 and the second structure 525 in adjoining proximity) suitable for dispensing UV adhesive. At this suitable distance, the UV robot 515 may apply UV adhesive on and / or near the tongue-and-groove junction formed by joining the first structure 523 and the second structure 525.

[0139] In some embodiments, a tool 549 connected to the UV robot 515 may apply the UV adhesive as one or more UV adhesive strips. Each UV adhesive strip may be applied to contact both the first structure 523 and the second structure 525. For example, the UV robot 515 may position the tool 549 such that one UV adhesive strip is placed across each of the surfaces of the first structure 523 (e.g., proximate the groove 533 of the first structure 523) and the second structure 525 (e.g., proximate the tongue 545 of the second structure 525). At this stage, the UV adhesive may be uncured (e.g., uncured UV adhesive 579).

[0140] Now referring to FIG. 6H, the main robot 507 and the assembly robot 511 can remain in their respective positions such that the second structure 525 and the first structure 523 are positioned in proximity to each other with the UV adhesive (e.g., uncured UV adhesive strip 579) positioned between the first structure 523 and the second structure 525.

[0141] In some embodiments, the UV robot 515 may again be positioned relatively close to the backbone robot 507 and the assembly robot 511. The distal end of the robot arm of the UV robot 515 may again be positioned towards the first structure 523 and the second structure 525, specifically towards a point where the first structure 523 and the second structure 525 are in junction proximity (e.g., towards the tongue and groove junction).

[0142] As mentioned above, the UV robot 515 may be connected to a tool 549 including a curing device, e.g., a UV light applicator 577, configured to cure a UV adhesive or other temporary adhesive previously applied by the UV robot 515. The UV light applicator 577 may be a UV curing tool configured to emit UV light 581 to cure the UV adhesive. In some other embodiments, the tool 549 may be configured to apply a temporary adhesive that can be quickly cured by other means, such as heat and / or air, and the tool may include an applicator sufficient to cure other temporary adhesives, such as an air dryer or an applicator with a heat source. In various embodiments, the temporary adhesive may be a fast-curing adhesive that cures quickly on its own, e.g., a quick-set epoxy, in which case the tool may include only an adhesive applicator.

[0143] As described in this embodiment, the tool 549 can include both a UV glue applicator configured to apply UV glue and a UV light applicator configured to cure the UV glue. For example, the UV robot 515 can switch the operation mode of the tool 549 from one mode for applying uncured UV glue to another mode for curing the UV glue. In some other embodiments, the tools can be different, for example, there can be separate tools for the UV glue applicator and the UV light applicator. For example, the UV robot 515 can switch from a UV glue applicator (dispenser) tool to a UV light applicator (curing) tool.

[0144] The UV robot 515 may position the tool 549 at a distance from the UV adhesive suitable for curing the UV adhesive, which may be the same or a different location from where the UV adhesive was previously applied. With the tool 549 at this distance, the UV robot 515 may cause the tool's UV light applicator 577 to cure the UV adhesive. For example, the UV robot 515 may cause the UV light applicator 577 to emit UV light 581 for a time sufficient to cure the UV adhesive. However, the UV robot 515 may not cure the structural adhesive, for example, because the structural adhesive may not be curable by exposure to UV light.

[0145] In some embodiments where UV adhesive (e.g., UV adhesive strips) are applied to multiple locations on the first structure 523 and the second structure 525, the UV robot 515 may move the tool 549 to different locations, each of which may be suitable for curing the UV adhesive. The UV robot 515 may hold the tool 549 at each of the different locations for a sufficient time to cure the UV adhesive while the UV light applicator 577 radiates UV light 581 for curing. After curing, the uncured UV adhesive 579 becomes cured UV adhesive 583.

[0146] Once the UV adhesive is cured, the UV robot 515 may move its robot arm away from the first structure 523 and the second structure 525. The first structure 523 and the second structure 525 may be at least temporarily bonded by the cured UV adhesive 583. However, the structural adhesive (applied by the structural adhesive robot 513 as described above in FIG. 6B) may be uncured at this stage.

[0147] 6I then shows that the resource robot 507 may remain in position and continue to hold the second structure 525. At this stage, the second structure 525 may be at least temporarily bonded to the first structure 523, for example, via a strip of UV adhesive 583 that has been cured across the first structure 523 and the second structure 525.

[0148] The assembly robot 511 may separate from the first structure 523. For example, the assembly robot 511 may cause the end effector 537 to disengage from the first structure 523, such as by opening the jaws of the end effector 537, disengaging the end effector 537 from one or more features of the first structure 523, and / or otherwise disengaging the end effector 537 from the first structure 523.

[0149] Once separated from the first structure 523, the assembly robot 511 may move its robot arm away from the first structure. For example, the assembly robot 511 may retract its robot arm away from the host robot 507. In doing so, the host robot 507 may be provided with a larger area in which to move.

[0150] When the assembly robot 511 is separated from the first structure 523, the master robot 507 may hold the first structure 523, for example, through its retention of the second structure 525 at least temporarily bonded to the first structure 523. The cured UV adhesive 583 may provide sufficient bonding to support this retention of the first structure 523 bonded to the second structure 525, even if the master robot 507 does not directly engage the first structure 523 (e.g., when the end effector 543 of the master robot 507 engages the second structure 525). When bonded (even temporarily), the first structure 523 and the second structure 525 may be one structure and / or may be referred to as a subassembly 603.

[0151] 6J, assembly robot 511 can face parts table 521 and engage third structure 527. Third structure 527 can include one or more features that enable mating of third structure 527 with one or more other structures. Illustratively, third structure 527 can include groove 551 on a first surface and groove 553 on a second surface. The first and second surfaces of third structure 527 can be substantially opposing surfaces (e.g., the first surface can be on a left side of third structure 527 and the second surface can be on a right side of third structure 527, or vice versa).

[0152] With its robot arm positioned towards the parts table 521, the assembly robot 511 may be relatively closer to the groove 551 of the third structure 527 than to the groove 553 of the third structure 527. The assembly robot 511 may, for example, engage the third structure 527 approximately on the side of the groove 551 of the third structure 527. Specifically, the robot arm of the assembly robot 511 may move to a position where an end effector 537 of the assembly robot 511 can engage the third structure 527. At this position, the end effector 537 of the assembly robot 511 engages the third structure 527. Once engaged, the assembly robot 511 may hold the third structure 527 by, for example, the end effector 537.

[0153] 6K, the assembly robot 511 may move towards the structural adhesive robot 513, such as by rotating its robot arm about its base to a position where its robot arm faces the robot arm of the structural adhesive robot 513. In some embodiments, the structural adhesive robot 513 may further move its robot arm towards a third structure 527 being held by the assembly robot 511.

[0154] As shown in FIG. 6K, the assembly robot 511 may orient the third structure 527 so that the groove 551 faces generally upward, such as by moving the assembly robot's robot arm and / or the assembly robot's end effector 537 so that the groove 551 faces generally upward.

[0155] A structural adhesive robot 513 coupled with a structural adhesive applicator 539 (or other similar tool) may move its robot arm to a position where the structural adhesive applicator is over groove 551 and close enough to deposit a controlled amount of structural adhesive within a defined area within the groove while avoiding deposition of structural adhesive elsewhere. In such position, the adhesive application tip of structural adhesive applicator 539 may be approximately directly over groove 551 and may be directed downward into the upwardly facing groove.

[0156] Once suitably positioned, structural adhesive robot 513 may cause structural adhesive applicator 539 to deposit a controlled amount of structural adhesive into groove 551. The controlled amount of structural adhesive may at least partially fill groove 551. In some embodiments, the controlled amount of structural adhesive may completely or nearly completely fill groove 551.

[0157] However, the amount of structural adhesive may be controlled such that the structural adhesive does not spill outside of groove 551 and onto a first surface of third structure 527 that borders groove 551. For example, the amount of structural adhesive deposited in groove 551 may be controlled such that the structural adhesive does not leak onto any surface of third structure 527 when third structure 527 is joined to another structure when a protrusion of the other structure is inserted into groove 551.

[0158] Continuing to FIG. 6L, the assembly robot 511 can rotate its robot arm relative to its base to a position where it is facing towards the robot arm of the main robot 507. Thus, the distal end of the robot arm of the main robot 507 can be positioned towards the assembly robot 511, and similarly, the distal end of the robot arm of the assembly robot 511 can be positioned towards the main robot 507.

[0159] The master robot 507 may hold the subassembly 603 with its end effector directly engaging the second structure 525 of the subassembly 603. The subassembly 603 may be positioned approximately between the two robots 507, 511. The master robot 507 may hold the subassembly 603 such that the tongue 535 of the first structure 523 is oriented facing the master robot 507.

[0160] After the assembly robot 511 rotates its robot arm away from the parts table 521 and towards the core robot 507, the third structure 527 may be positioned approximately between the assembly robot 511 and the core robot 507. The assembly robot 511 may orient the third structure 527 so that the groove 551 is approximately facing upward and has a controlled amount of adhesive pre-deposited therein.

[0161] The assembly robot 511 may move the third structure 527 according to one or more vectors, which may be based on CAD modeling. Each of the one or more vectors may indicate a magnitude (e.g., distance) and a direction according to which the third structure 527 is moved by the assembly robot 511. Each vector may be intended to direct the third structure 527 towards a joining vicinity where the third structure 527 may join with the subassembly 603, while some vectors may be intermediate vectors intended to direct the first structure 523 to a position where vectors for joining the first and second structures 523, 525 are applicable.

[0162] 6M, the core robot 507 may move the subassembly 603 to a position where the tongue 535 of the first structure 523 faces approximately downward. For example, the core robot 507 may rotate the subassembly 603 approximately 90 degrees counterclockwise from the position of the subassembly 603 when the first structure 523 is mated with the second structure 525 (e.g., as shown above in FIG. 6I). In such an orientation, the tongue 535 of the first structure 523 faces downward toward the upwardly oriented groove 551 of the third structure 527.

[0163] In some embodiments, the master robot 507 may move the subassembly 603 according to one or more vectors, which may be based on CAD modeling. Each of the one or more vectors may indicate a magnitude (e.g., distance) and direction according to which the subassembly 603 is to be moved by the master robot 507. Each vector may be intended to bring the subassembly 603 into proximity where it can join with the third structure 527, while some vectors may be intermediate vectors intended to bring the subassembly 603 to a position where a vector for joining the subassembly 603 with the third structure 527 can be applied.

[0164] Next, FIG. 6N illustrates that the assembly robot 511 and the main robot 507 may position the third structure 527 and the subassembly 603, respectively, so that the third structure and the subassembly are adjacent but not in joint proximity, in this case the third structure is at least partially below the first structure 523, for example, so that the third structure 527 and the subassembly 603 at least partially overlap in the elevation plane (or vertical space).

[0165] The third structure 527 may be oriented such that the grooves 551 face generally upward, with a controlled amount of adhesive pre-deposited thereon. The assembly robot 511 may move the third structure 527 upward toward the subassembly 603. Further, the assembly robot 511 may position the third structure 527 such that the upward facing grooves 551 are generally vertically and horizontally aligned with the downward facing tongues 535.

[0166] The master robot 507 may hold the subassembly 603 in the position previously described, with the tongue 535 oriented generally downward toward the upward groove 551. However, the third structure 527 and the subassembly 603 may not yet be within a joint vicinity where the third structure 527 and the subassembly 603 may be joined.

[0167] 6O illustrates that the subassembly 603 and the third structure 527 may be brought into a joint vicinity where the subassembly and the third structure may be joined. To do so, one or both of the subassembly 603 and / or the third structure 527 may be moved by one or both of the master robot 507 and / or the assembly robot 511, respectively. For example, the assembly robot 511 may move a distal end of its robot arm, to which the third structure 527 is engaged, in a generally upward direction toward the subassembly 603. Additionally or alternatively, the master robot 507 may move a distal end of its robot arm, to which the subassembly 603 is held, in a generally downward direction toward the third structure 527.

[0168] 6F , metrology system 531 may determine position data associated with at least one of subassembly 603 and / or third structure 527 within assembly cell 505. For example, metrology system 531 may determine a set of coordinates associated with third structure 527. The set of coordinates may indicate a physical location of third structure 527 within assembly cell 505 and / or a relative location with respect to a joint vicinity or subassembly 603.

[0169] The metrology system 531 may provide the position data to the computing system 529. The computing system 529 may receive the position data and, based on the position data, may determine a set of corrective operations to apply, such as by inserting the tongue 535 of the first structure 523 into the groove 551 of the third structure 527 with the structural adhesive, to guide the third structure 527 into the joint vicinity so that it can be joined with the subassembly 603. For example, the computing system 529 may determine a difference between a set of coordinates associated with the third structure 527 and the joint vicinity.

[0170] Based on the determined difference, the computing system 529 may determine a set of corrective operations to be applied to the third structure 527 such that the third structure may be brought into the vicinity of the joint. In some embodiments, the set of corrective operations may include a set of vectors indicating a magnitude and a direction, respectively, that the third structure 527 may be moved into the vicinity of the joint. In some other embodiments, the set of corrective operations may include a set of coordinates associated with bringing the third structure 527 into the vicinity of the joint, such as a set of coordinates to which a robot arm of the assembly robot 511 should be controlled such that the third structure 527 is brought into the vicinity of the joint.

[0171] The computing system 529 may provide the set of corrective operations to a controller 611 communicatively coupled to the assembly robot 511, such as by issuing a set of commands to the controller 611. The controller 611 may apply the set of commands by controlling a robotic arm of the assembly robot 511 according to the set of corrective operations indicated by the set of commands.

[0172] In some embodiments, the computing system 529 may receive position data from the metrology system 531 indicating that the subassembly 603 and the third structure 527 are in bonding proximity. For example, the computing system 529 may determine from the received position data that the third structure 527 is positioned within an acceptable tolerance for bonding the third structure 527 and the subassembly 603. The acceptable tolerance may be provided by a bond gap similar to the bond gap shown in FIG. 6F. However, in the bonding operation shown in FIG. 6O, the lateral bond gaps are not equal. Specifically, the first lateral bond gap 565 is larger than the second lateral bond gap 566. The difference in size between the first and second lateral bond gaps may arise, for example, because the tongue was erroneously printed to be offset to one side (from the perspective of the figure). However, because the bond gap allows for some dimensional error, the final position of the remaining portion of the subassembly 603 may be accurately positioned relative to the third structure 527. In this way, for example, bond gaps resulting from non-contact bonding can offset dimensional errors, allowing large multi-structure assemblies to have higher dimensional accuracy. Particularly in the automotive field, dimensional accuracy is a key factor in achieving high quality structures. Thus, fixtureless bonding of automotive structures without contact can provide significant advantages.

[0173] 6P, the UV robot 515 may be positioned relatively close to the backbone robot 507 and the assembly robot 511. The distal end of the robot arm of the UV robot 515 may be positioned toward the subassembly 603 and the third structure 527, specifically toward a point where the subassembly 603 and the third structure 527 are located in junction proximity (e.g., toward the tongue-and-groove junction). In such a position, the distal end of the robot arm of the UV robot 515 may be between the backbone robot 507 and the assembly robot 511.

[0174] The distal end of the robot arm of the UV robot 515 may be positioned such that the tool 549 is proximate a point at which the subassembly 603 and the third structure 527 are in junction proximity. For example, the robot arm of the UV robot 515 may be positioned such that the tool 549 is spaced a distance from a tongue-and-groove junction (formed by the subassembly 603 and the third structure 527 in junction proximity) suitable for dispensing UV adhesive.

[0175] At this suitable distance, the UV robot 515 may apply UV adhesive on and / or near the tongue-and-groove joint formed by positioning the subassembly 603 and the third structure 527 in joint proximity. For example, the UV adhesive applicator 575 of the tool 549 may apply the UV adhesive as one or more UV adhesive strips, each of which may contact both the first structure 523 and the third structure 527 of the subassembly 603. For example, the UV robot 515 may position the tool 549 such that one UV adhesive strip is placed across each surface of the first structure 523 (e.g., proximate the tongue 535 of the first structure 523) and the third structure 527 (e.g., proximate the groove 551 of the third structure 527). At this stage, the UV adhesive may be uncured (e.g., uncured UV adhesive 585).

[0176] Continuing with FIG. 6Q, the UV robot 515 may position the UV light applicator 577 of the tool 549 at a distance from the uncured UV adhesive 585 suitable for curing the UV adhesive, which may be the same or a different location from where the UV adhesive was previously applied (as shown above in FIG. 6P). With the tool 549 at this distance, the UV robot 515 may cause the UV light applicator 577 to cure the UV adhesive. For example, the UV robot 515 may cause the UV light applicator 577 to emit UV light 581 for a time sufficient to cure the UV adhesive, resulting in a cured UV adhesive 587. However, the UV robot 515 may not cure the structural adhesive applied by the structural adhesive robot 513 (as shown in FIG. 6K), for example, because the structural adhesive may not be curable by exposure to UV light.

[0177] In some embodiments where UV adhesive (e.g., UV adhesive strips) are applied to multiple locations on the subassembly 603 and the third structure 527, the UV robot 515 may move the tool 549 to different locations, each of which may be suitable for curing the UV adhesive applied to different locations across the subassembly 603 and the third structure 527. The UV robot 515 may hold the tool 549 at each of the different locations for a sufficient time to cure the UV adhesive while the UV light applicator 577 radiates UV light 581 for curing.

[0178] Figure 6R then shows that once the UV adhesive is cured, UV robot 515 may move its robot arm away from subassembly 603 and third structure 527. Subassembly 603 and third structure 527 may be at least temporarily bonded by cured UV adhesive 587 to form subassembly 605. However, the structural adhesive (applied by structural adhesive robot 513 as described above in Figure 6K) may still be uncured at this stage.

[0179] The core robot 507 can remain in its position and continue to hold the subassembly 605. The assembly robot 511 may disengage from the third structure 527. For example, the assembly robot 511 may disengage the end effector 537 from the third structure 527, such as by opening the jaws of the end effector, removing the end effector from one or more features of the third structure, and / or otherwise disengaging the end effector from the third structure.

[0180] Once separated from the third structure 527, the assembly robot 511 may move its robot arm away from the third structure 527. For example, the assembly robot 511 may retract its robot arm away from the host robot 507. In doing so, the host robot 507 may be provided with a larger area to move while holding the subassembly 605.

[0181] When the assembly robot 511 is separated from the third structure 527, the master robot 507 may hold the third structure 527, for example, through its retention of the second structure 525, which is at least temporarily bonded to the first structure 523, and through at least a temporary bonding between the first structure 523 and the third structure 527. The cured UV adhesive 587 may provide sufficient bonding to support this retention of the third structure 527, which is bonded to the first structure 523 and indirectly connected to the second structure 525 through its bonding to the first structure 523, even if the master robot 507 does not directly engage the first structure 523 (e.g., when the end effector 543 of the master robot 507 engages the second structure 525). When bonded (even temporarily), the first structure 523, the second structure 525, and the third structure 527 may be one structure and / or may be referred to as a subassembly, i.e., subassembly 605.

[0182] The robot may repeat exemplary operations of the fixtureless assembly system 500 similar to those described above in FIGS. 6A-6R to fixturelessly assemble a subassembly that is at least a portion of a vehicle, such as a frame, chassis, body, panel, etc. During exemplary operations, the core robot 507 may hold the subassembly in succession as the assembly robot 511 (and / or assembly robot 509) engages and holds other structures, the structural adhesive robot 513 applies structural adhesive to each of the other structures, the assembly robot 511 (and / or assembly robot 509) bonds each of the other structures to the subassembly held by the core robot 507, the UV robot 515 applies and cures a UV or other temporary adhesive to at least temporarily bond the subassembly to each of the joined other structures, and the assembly robot 511 (and / or assembly robot 509) releases each of the other structures after the UV or other temporary adhesive has cured.

[0183] As shown in FIG. 6S, the subassembly 637 is assembled through exemplary operations such as joining the first structure 523 and the second structure 525 to form the subassembly 603, and joining the third structure 527 and the subassembly 603 to form the subassembly 605. In this example, the master robot 507 previously disengaged from the second structure 525 during a previous step in joining the subassembly 637. For example, the master robot may have disengaged to allow the assembly robot to hold the previous subassembly, and the master robot may have picked up another part from the parts table to continue the assembly process. The bond created by the UV or other temporary adhesive may be sufficient to support the subassembly 637 when held by the master robot 507 (e.g., by only one end effector and at only one structure). The master robot 507 may be effectively capable of holding and supporting the subassembly 637 (as well as larger, heavier, and / or more complex subassemblies and completed assemblies) on its own. Additionally, the core robot 507 may be capable of moving subassembly 637 (as well as larger, heavier, and / or more complex subassemblies and completed assemblies) without assistance from other robots. For example, the core robot 507 may be able to move, rotate, and / or otherwise articulate its robot arm and / or end effector 543 while holding the subassembly 637. When the final assembly is completed, the core robot 507 holds the entire assembly, as described with respect to FIG. 6T.

[0184] In some embodiments, other subassemblies may be assembled from other structures without the core robot 507. For example, the assembly robots 509, 511 may assemble another subassembly 639 from another set of structures similar to the assembly of the subassembly 605 from the first, second, and third structures 523, 525, 527. However, the subassembly 639 may be assembled without the core robot 507. Alternatively, the assembly robot 511 may engage and continuously hold one structure as the assembly robot 509 engages and holds the other structures, the structural adhesive robot 513 applies structural adhesive to each of the other structures, the assembly robot 509 bonds each of the other structures to the subassembly 639 while being continuously held by the assembly robot 511, the UV robot 515 applies and cures UV adhesive to at least temporarily bond the subassembly 639 to each of the bonded other structures, and then the assembly robot 509 releases each of the other structures after the UV adhesive has cured. In this manner, the subassembly 639 may be assembled in the assembly cell 505 while the backbone robot 507 continuously holds the subassembly 637. In some embodiments, at least two subassemblies may then be assembled simultaneously in the fixtureless assembly system 500.

[0185] Referring again to FIG. 6S, assembly robot 511 may be positioned, for example, to be at least below subassembly 637 such that subassembly 639 and subassembly 637 at least partially overlap in the elevation plane (or vertical space).

[0186] Subassembly 639 may be oriented such that its component grooves 621, 623 face approximately upward. The grooves 621, 623 of subassembly 639 may have a controlled amount of construction adhesive pre-deposited therein. The assembly robot 511 may move subassembly 639 upward toward subassembly 637. Additionally, assembly robot 511 may position subassembly 639 such that the upward facing grooves 621, 623 are approximately or nearly vertically and horizontally aligned with the downward facing tongues 625, 627 of subassembly 637.

[0187] The backbone robot 507 can hold the subassembly 637 in a position where the tongues 625, 627 of the subassembly 637 face generally downward toward the generally upward grooves 621, 623 of the subassembly 639. However, the subassemblies 637, 639 may not yet be within mating proximity where the subassembly 637 can mate with the subassembly 639.

[0188] 6T, subassembly 637 and subassembly 639 may be brought into a joint vicinity where subassembly 637 and subassembly 639 may be joined. To do so, one or both of subassembly 637 and / or subassembly 639 may be moved by one or both of master robot 507 and / or assembly robot 511, respectively. For example, assembly robot 511 may move a distal end of its robot arm, with which subassembly 639 is engaged, generally upward toward subassembly 637. Additionally or alternatively, master robot 507 may move a distal end of its robot arm, with which subassembly 637 is held, generally downward toward subassembly 639.

[0189] 6F, metrology system 531 may determine position data associated with at least one of subassembly 637 and / or subassembly 639 in assembly cell 505. Metrology system 531 may provide the position data to computing system 529. Computing system 529 may receive the position data and, based on the position data, determine a set of corrective operations to apply to guide subassembly 639 into joint proximity to be joined with subassembly 637, specifically by inserting tongue 535 of first structure 523 into respective ones of grooves 621, 623 of subassembly 639 having structural adhesive applied therein.

[0190] Based on the position data, the computing system 529 may determine a set of corrective operations to be applied to the subassembly 639 so that the subassembly 639 may be directed within the interface vicinity. In some embodiments, the set of corrective operations may include a set of vectors that respectively indicate a magnitude and a direction in which the subassembly 639 may be moved within the interface vicinity. In some other embodiments, the set of corrective operations may include a set of coordinates related to directing the subassembly 639 within the interface vicinity, such as a set of coordinates to which a robot arm of the assembly robot 511 should be controlled so that the subassembly 639 is directed within the interface vicinity.

[0191] The computing system 529 may provide the set of corrective operations to a controller 611 communicatively coupled to the assembly robot 511, such as by issuing a set of commands to the controller 611. The controller 611 may apply the set of commands by controlling a robotic arm of the assembly robot 511 according to the set of corrective operations indicated by the set of commands.

[0192] In some embodiments, computing system 529 may receive position data from metrology system 531 indicating that subassembly 637 and subassembly 639 are within mating proximity. For example, computing system 529 may determine from the received position data that subassembly 639 is positioned within an acceptable tolerance for mating subassembly 637 and subassembly 639. The acceptable tolerance may be provided by a bond gap of grooves 621, 623 of subassembly 639.

[0193] When the computing system 529 determines, based on the position data received from the metrology system 531, that the subassembly 637 and the subassembly 639 are in a joint vicinity and that no further modification operations should be applied, the subassembly 637 and the subassembly 639 may be joined in the joint vicinity. For example, the assembly robot 511 may move the subassembly 639 in a generally upward direction and / or the articulated robot 507 may move the subassembly 637 in a generally downward direction such that at least a portion of the subassembly 637 overlaps with at least a portion of the subassembly 639 in at least one of the azimuth (or horizontal) plane and / or the elevation plane. With such overlap in the joint vicinity, each of the tongues 625, 627 of the subassembly 637 may be positioned within a respective one of the grooves 621, 623 of the subassembly 639, forming a tongue and groove joint.

[0194] In some embodiments, the tongues 625, 627 of the subassembly 637 may not contact the subassembly 639 in the joint vicinity. For example, the tongues 625, 627 of the subassembly 637 may be within the grooves 621, 623, respectively, of the subassembly 639, but bond gaps in the sides and bottom surfaces of the grooves 621, 623, respectively, may allow the tongues 625, 627 to be inserted without contacting any surfaces of the subassembly 639, such as the sides and bottom surfaces of the grooves 621, 623. Rather, the tongues 625, 627 of the subassembly 637 may contact the structural adhesive deposited in the grooves 621, 623 of the subassembly 639 when the subassemblies 637, 639 are in joint vicinity. However, in some further embodiments, the surfaces surrounding the grooves 621, 623 of the subassembly 639 may contact the surfaces surrounding the tongues 625, 627 of the subassembly 637.

[0195] The distal end of the robot arm of the UV robot 515 may then be positioned toward the subassemblies 637, 639, specifically toward one of the points where the subassemblies 637, 639 are joined (e.g., toward one of the tongue and groove joints). The distal end of the robot arm of the UV robot 515 may be positioned such that a tool 549 connected to the UV robot 515 is proximate the point where the subassemblies 637, 639 are located at the joint proximate.

[0196] When at an appropriate distance, the UV robot 515 may apply UV adhesive on and / or near one of the tongue-and-groove joints formed by joining the subassemblies 637, 639. For example, a tool 549 connected to the UV robot 515 may apply the UV adhesive as one or more UV adhesive strips, each of which may contact both subassemblies 637, 639.

[0197] The UV robot 515 may then move the tool 549 to the other tongue and groove joint formed by joining the subassemblies 637, 639. The UV robot 515 may then apply UV adhesive on and / or near one of the other tongue and groove joints formed by joining the subassemblies 637, 639. For example, the tool 549 in communication with the UV robot 515 may apply the UV adhesive as one or more UV adhesive strips, each of which may contact both subassemblies 637, 639.

[0198] The UV robot 515 may then position the tool 549 to cure the UV adhesive at each point where the UV adhesive is applied. When the tool 549 is at each point, the UV robot 515 may cause the tool 549 to cure the UV adhesive. For example, the UV robot 515 may cause the tool 549 to emit UV light 581 at each point for a time sufficient to cure the UV adhesive. However, the UV robot 515 may not cure the structural adhesive applied to the grooves 621, 623, for example, because the structural adhesive may not be curable by exposure to UV light.

[0199] Once the UV adhesive is cured, the UV robot 515 can move its robot arm away from the subassemblies 637, 639. The subassemblies 637, 639 may be at least temporarily bonded together by the cured UV adhesive.

[0200] After the UV adhesive cures, the assembly robot 511 may separate from the subassembly 639 and move its robot arm away from the subassembly 639. The joined, at least temporarily bonded, subassemblies 637, 639 may form an assembly 641. Once the assembly robot 511 is separated from the assembly 641, the backbone robot 507 may hold the assembly 641.

[0201] 6U next shows the core robot 507 rotating its robot arm away from the assembly robot 511. In doing so, the core robot 507 may direct the assembly 641 towards the automated cart 631. The core robot 507 may move its robot arm and / or end effector 543 to position the assembly 641 on the automated cart 631. For example, the core robot 507 may rotate its robot arm about its base to bring the assembly 641 onto the automated cart 631, and the core robot 507 may then move its robot arm generally downward to lower the assembly 641 into the automated cart 631 until the assembly 641 is within and touching a surface of the automated cart 631.

[0202] The core robot 507 may separate from the assembly 641 after the core robot 507 positions the assembly 641 within the automated cart 631. The core robot 507 may then retract its robot arm away from the assembly 641.

[0203] 6V, the automated cart 631 may then move the assembly 641 to an oven 633, where the assembly 641 can be placed in the oven 633. The oven 633 may be configured to heat to a suitable temperature to cure the structural adhesive, and the oven 633 may be configured to remain at that temperature for a period of time sufficient to cure the structural adhesive.

[0204] In some embodiments, UV adhesive previously applied to temporarily bond structures to form assembly 641 (e.g., UV adhesive strips) may be disintegrated or otherwise burned off by exposing the UV adhesive to the temperature of oven 633 for a period of time sufficient to cure the structural adhesive. After a period of time sufficient to cure the structural adhesive, assembly 641 may be removed from oven 633. Assembly 641 may then be included in a vehicle, for example, as a frame, chassis, body, panel, or other vehicle component.

[0205] 7 is a flow diagram of a method 700 of a fixtureless assembly system including at least two robots. One or more of the illustrated operations may be interchanged, omitted, and / or performed simultaneously.

[0206] Method 700 may be performed in a fixtureless assembly system, such as fixtureless assembly system 500 of FIG. 5, including those of FIG. 6A-6V. In some embodiments, a computing system may perform method 700, such as by one or more of controllers 607, 609, 611, 613, 615, 617 and / or computing system 529, which may be, for example, a processing system, such as processing system 1000 described below. A computing system performing method 700 may include a memory and at least one processor coupled to the memory, where the at least one processor may be configured to perform operations of method 700. A computer performing method 700 may be communicatively coupled to one or more of the switches and / or one or more robots (e.g., one or more of robots 507, 509, 511, 513, 515, 517). The computing system may be communicatively coupled to one or more of the aforementioned components via one or more networks.

[0207] As an example, a computing system performing method 700 may include at least one controller communicatively coupled to a resource robot. The computing system may direct a first robot arm to a first location based on a first set of coordinates (block 703). The computing system may cause the first robot arm to engage a first structure based on the first location of the first robot arm (block 705). Additionally, the computing system may direct the first robot arm to a second location based on a second set of coordinates such that the first structure is brought into mating proximity of the second structure without a fixture holding the first structure and without a fixture holding the second structure, the first structure being configured to mating with the second structure when the first structure and the second structure are in mating proximity, the mating proximity being a proximity such that the first structure and the second structure can mating together (block 707).

[0208] 8 is a flow diagram of a method 800 of a fixtureless assembly system including at least two robots. One or more of the illustrated operations may be interchanged, omitted, and / or performed simultaneously.

[0209] Method 800 may be performed in a fixtureless assembly system, such as fixtureless assembly system 500 of FIG. 5, including those of FIG. 6A-6V. In some embodiments, a computing system may perform method 800, such as by one or more of controllers 607, 609, 611, 613, 615, 617 and / or computing system 529, which may be, for example, a processing system, such as processing system 1000 described below. A computing system performing method 800 may include a memory and at least one processor coupled to the memory, where the at least one processor may be configured to perform operations of method 800. A computer performing method 800 may be communicatively coupled to one or more of the switches and / or one or more robots (e.g., one or more of robots 507, 509, 511, 513, 515, 517). The computing system may be communicatively coupled to one or more of the aforementioned components via one or more networks.

[0210] The computing system may orient the first robotic arm to a first location based on the first set of coordinates (block 803). The computing system may cause the first robotic arm to engage a first structure based on the first location of the first robotic arm (block 805). For example, the first structure may have a volume of 500 milliliters or more and / or the first structure may have a weight of 100 grams or more. The first structure may include a portion of a chassis of a vehicle. In one embodiment, the first robotic arm may engage the first structure with an end effector that is removable from the first robotic arm. In another embodiment, the first robotic arm may engage the first structure with an end effector that is integral with the first robotic arm.

[0211] The computing system may then direct the first robotic arm to a second location based on the second set of coordinates such that the first structure is brought into joint proximity of the second structure without a fixture to hold the first structure and without a fixture to hold the second structure, the first structure being configured to be joined with the second structure when the first structure and the second structure are in joint proximity, the joint proximity being close enough that the first structure and the second structure can be joined together (block 807). In some embodiments, at least one of the first set of coordinates or the second set of coordinates is based on a move-measure-fix procedure. For example, the move-measure-fix procedure may be based on laser measurements.

[0212] The computing system may then instruct bonding the first structure and the second structure when in mating proximity (block 809). The second structure may be engaged by a second robotic arm, which may be configured to engage the second structure when the first structure is brought into mating proximity. In some embodiments, the second structure may include a recess, and a structural adhesive may be deposited in the recess of the second structure. The first structure may include a protrusion, and the protrusion may be inserted into the recess of the second structure at the second location. In some embodiments, the first structure and the second structure are bonded without contact, for example, with a structural adhesive.

[0213] The computing system may cause a first adhesive to be applied to at least one surface of at least one of the first structure or the second structure, and the first structure and the second structure may be joined at the at least one surface of at least one of the first structure or the second structure to which the first adhesive is applied (block 811). The first structure and the second structure may be joined with the first adhesive. In some embodiments, the first adhesive may be curable by exposure to UV light. Thus, the computing system may cause the first adhesive to be cured (block 813).

[0214] In some further embodiments, the computing system may cause a second adhesive to be applied to at least one surface of at least one of the joined first and second structures or the third structure (block 815). The computing system may cause the joined first and second structures to be bonded to a third structure at the at least one surface of at least one of the joined first and second structures or the third structure to which the second adhesive has been applied (block 817). Additionally, the computing system may cause the second adhesive to cure (block 819).

[0215] The method 800 may be repeated iteratively such that the set of structures is joined, after which the structural adhesive applied to a subset of the set of structures may be cured (e.g., in an oven) to bond the assembly together.

[0216] 9 is a flow diagram of a method 900 of a fixtureless assembly system including at least two robots. One or more of the illustrated operations may be interchanged, omitted, and / or performed simultaneously.

[0217] Method 900 may be performed in a fixtureless assembly system, such as fixtureless assembly system 500 of FIG. 5, including those of FIG. 6A-6V. In some embodiments, a computing system may perform method 900, such as by one or more of controllers 607, 609, 611, 613, 615, 617 and / or computing system 529, which may be, for example, a processing system, such as processing system 1000 described below. A computing system performing method 900 may include a memory and at least one processor coupled to the memory, where the at least one processor may be configured to perform operations of method 900. A computer performing method 900 may be communicatively coupled to one or more of the switches and / or one or more robots (e.g., one or more of robots 507, 509, 511, 513, 515, 517). The computing system may be communicatively coupled to one or more of the aforementioned components via one or more networks.

[0218] The computing system may cause a first robotic arm to engage a first part (block 903). Then, the computing system may cause the first robotic arm to move the first part to a position where it can be joined with a second part (block 905). Additionally, the computing system may cause the first robotic arm to move to a position where it can apply structural adhesive, the position where it can apply structural adhesive being different from the position where it can be joined with the second part (block 907).

[0219] The computing system may cause the second robotic arm to apply a structural adhesive to the first part before the first part is moved to a position where it can be joined with the second part (block 909). The computing system may cause the third robotic arm to engage the second part (block 911). Additionally, when the first part is in a position where it can be joined with the second part, the computing system may cause the third robotic arm to move the second part to a position where it can be joined with the first part (block 913).

[0220] The computing system may cause the fourth robotic arm to apply a temporary adhesive across the first part and the second part when the first part is in position to join with the second part (block 915). The computing system may cause the fourth robotic arm to cure the temporary adhesive when the temporary adhesive is applied across the first part and the second part (block 917).

[0221] With reference to FIG. 10, a block diagram illustrates one embodiment of a processing system 1000. The processing system 1000 may include at least one controller associated with at least one robot. For example, with reference to FIG. 5, the processing system 1000 may be an embodiment of at least one of the controllers 607, 609, 611, 613, 615, 617 associated with at least one of the robots 507, 509, 511, 513, 515, 517. In another example, with reference to FIGS. 6A-6V, the processing system 1000 may be an embodiment of all of the controllers 607, 609, 611, 613, 615, 617.

[0222] System 1000 may include various types of machine-readable media and interfaces. As shown, system 1000 includes at least one interconnect 1020 (e.g., at least one bus), a persistent storage device 1022, a random access memory (RAM) 1024, at least one controller interface 1026, a read only memory (ROM) 1028, at least one processor 1030, and a network component 1032.

[0223] The interconnect 1020 may communicatively couple components and / or devices collocated with the system 1000, such as internal components and / or devices within an enclosure of the system 1000. For example, the interconnect 1020 may communicatively couple the processor 1030 to the persistent storage device 1022, the RAM 1024, and / or the ROM 1028. The processor 1030 may be configured to access and load computer-executable instructions from at least one of the persistent storage device 1022, the RAM 1024, and / or the ROM 1028.

[0224] Persistent storage 1022 may be non-volatile memory that stores instructions and data regardless of the power state (e.g., on or off) of system 1000. For example, persistent storage 1022 may be a hard disk, a flash drive, or other read / write memory device.

[0225] ROM 1028 may store static instructions that enable basic functionality of system 1000 and components therein. For example, ROM 1028 may store instructions for processor 1030 to execute a set of processes related to a robot of at least a portion of a vehicle, such as, for example, as described with respect to one or more of the robots above. Examples of ROM 1028 may include erasable programmable ROM (EPROM) or electrical EPROM (EEPROM), compact disc ROM (CD-ROM) or other optical disk storage, magnetic disk storage or other magnetic storage devices, and / or other computer-accessible and computer-readable media that may store program code as instructions and / or data structures.

[0226] The RAM 1024 may include volatile read / write memory. The RAM 1024 may store computer-executable instructions associated with run-time operation by the processor 1030. Additionally, the RAM 1024 may store real-time data captured during assembly of at least a portion of a vehicle, for example, as described with respect to one or more of Figures 5-9 above.

[0227] The processor 1030 may be implemented with one or more general purpose and / or special purpose processors. Examples of general purpose and / or special purpose processors may include a microprocessor, a microcontroller, a DSP processor, and / or any other suitable circuitry configured to execute instructions loaded from at least one of the persistent storage device 1022, the RAM 1024, and / or the ROM 1028. Alternatively or additionally, the processor 1030 may be implemented as dedicated hardware, such as at least one field programmable gate array (FPGA), at least one programmable logic device (PLD), at least one controller, at least one state machine, a set of logic gates, at least one discrete hardware component, or any other suitable circuitry and / or combination thereof.

[0228] The interconnect 1020 may further communicatively couple the system 1000 to one or more controller interfaces 1026. The controller interface 1026 may communicatively couple the system 1000 to various circuitry associated with one or more robots, for example, during assembly of at least a portion of a vehicle. Instructions executed by the processor 1030 may be communicated to the robot via the controller interface 1026, which may cause movement and / or other operations of the robot in connection with assembly of at least a portion of a vehicle. For example, instructions executed by the processor 1030 may cause signals to be sent to the circuitry of the robot and / or other machinery via the controller interface 1026 to direct movement and / or other actions of the robot in connection with assembly of at least a portion of a vehicle.

[0229] In some embodiments, system 1000 may include a network component 1032. Network component 1032 may be configured to communicate over a network, for example, to send and / or receive instructions related to assembly of at least a portion of a vehicle. Instructions communicated over the network via network component 1032 may include instructions related to assembly of at least a portion of a vehicle and may be communicated before, during, and / or after assembly of at least a portion of a vehicle. Examples of networks with which network component 1032 may communicate may include a local area network (LAN), a wide area network (WAN), the Internet, an intranet, or another wired or wireless network.

[0230] Various aspects described herein may be implemented at least in part as a software process of a computer programming product. Such a process may be specified as a set of instructions recorded on a machine-readable storage medium. When the set of instructions is executed by the processor 1030, the set of instructions can cause the processor to perform the operations indicated and recorded in the set of instructions.

[0231] This disclosure is provided to enable those skilled in the art to practice the various aspects described herein. Various modifications to these exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to other technologies for printing nodes and interconnects. Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout this disclosure, but should be accorded the full scope consistent with the language of the claims. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or will become known to those skilled in the art are intended to be within the scope of the claims. Furthermore, nothing disclosed herein is intended to be dedicated to the public, regardless of whether such disclosure is expressly set forth in the claims. No element of a claim shall be construed under the provisions of 35 U.S.C. 112(f) or under any analogous law of any applicable jurisdiction, unless that element is expressly recited using the phrase "means for" or, in a method claim, unless that element is recited using the phrase "step for."

Claims

1. a first robotic arm; a second robotic arm; and A processor communicatively coupled to the memory; 11. An apparatus comprising: engaging the first robotic arm with the first structure without a fixture holding the first structure; engaging the second robotic arm with the second structure without a fixture holding the second structure; directing the first robot arm and the second robot arm to move the first structure and the second structure such that a protrusion of the first structure or an opening of the second structure is directed to a position where the first structure and the second structure can be joined together, wherein the protrusion does not contact the second structure or the opening does not contact the first structure; joining the first structure and the second structure at the protrusion or the opening; An apparatus configured to cause

2. The apparatus of claim 1 , wherein the first structure is bonded to the second structure with a first adhesive.

3. the second robotic arm configured to cure the first adhesive with a curing device. The apparatus of claim 2 , further comprising:

4. The apparatus of claim 2 , wherein the first adhesive is cured by exposure to ultraviolet light.

5. The processor, applying the first adhesive to at least one surface of at least the first structure or the second structure, such that the first structure and the second structure are joined at the at least one surface of the first structure or the second structure to which the first adhesive is applied; curing the first adhesive; and The apparatus of claim 2 , further configured to:

6. The processor, applying a second adhesive to at least one surface of at least the joined first and second structures or the third structure; bonding the bonded first and second structures to the third structure at at least one surface of the bonded first and second structures or the third structure to which the second adhesive is applied; curing the second adhesive; and The apparatus of claim 5 , further configured to:

7. The apparatus of claim 6 , wherein each of the first and second adhesives comprises a fast-curing adhesive, the fast-curing adhesive being cured by exposure to ultraviolet (UV) light.

8. The apparatus of claim 1 , wherein indicating at least one of the first structure or the second structure is based on a move-measure-correct procedure.

9. The apparatus of claim 8 , wherein the move-measure-correct procedure is based on laser metrology.

10. The device of claim 1 , wherein the opening comprises a recess and the protrusion is inserted into the recess.

11. The apparatus of claim 10 , wherein an adhesive is deposited in the recess of the second structure, and the protrusion of the first structure is bonded to the second structure by the adhesive.

12. The processor, to bond the first structure and the second structure without contact between the first structure and the second structure; The apparatus of claim 1 further comprising:

13. The apparatus of claim 12 , wherein the first structure and the second structure are joined without contact using an adhesive.

14. The apparatus of claim 1 , wherein the first robotic arm engages the first structure with an end effector that is removable from the first robotic arm.

15. The apparatus of claim 1 , wherein the first robotic arm engages the first structure with an end effector integral with the first robotic arm.

16. The apparatus of claim 1 , wherein the first structure has a volume of 500 milliliters or greater.

17. The apparatus of claim 1 , wherein the first structure has a weight of 100 grams or more.

18. The apparatus of claim 1 , wherein the first structure comprises a portion of a chassis of a vehicle.

19. The processor, causing the first robotic arm to disengage the first structure; engaging a third structure with the first robotic arm, the third structure being a different structure than the first structure; and moving the third structure to a position where the third structure can be joined to a subassembly including the first and second structures by the first robot arm; The apparatus of claim 1 , further configured to:

20. 20. The apparatus of claim 19, wherein the second robotic arm is configured to fixturelessly hold the subassembly on the second structure through a fixtureless assembly process during which a number of other parts are joined to the subassembly.

21. a third robotic arm, the processor further comprising: The apparatus of claim 1 , further configured to cause the third robotic arm to apply a temporary adhesive to the first structure or the second structure.

22. The processor, causing the third robot arm to cure the temporary adhesive; 22. The apparatus of claim 21 further comprising:

23. a tool configured to emit ultraviolet (UV) light, the tool being connected to the third robotic arm; 23. The apparatus of claim 22, wherein the temporary adhesive comprises an ultraviolet curable adhesive, and the third robotic arm is configured to cure the temporary adhesive by controlling the tool to emit ultraviolet light directed at the temporary adhesive.

24. a fourth robotic arm, the processor further comprising: moving the first robot arm to a position where a structural adhesive can be applied, the position where the structural adhesive can be applied being different from a position where the first structure can be joined to the second structure; The apparatus of claim 1 , further configured to:

25. The apparatus of claim 24, wherein the structural adhesive is applied to a surface of the first structure or the second structure.

26. 9. The apparatus of claim 8, further comprising a metrology system configured to obtain position data related to the first structure, and wherein applying the move-measure-correct procedure is based on the position data.

27. 1. A computer-readable medium storing computer-executable code for controlling one or more robotic arms in a fixtureless assembly system, the code, when executed by at least one processor, causing the at least one processor to: engaging a first robotic arm with a first structure without a fixture holding the first structure; engaging a second robotic arm with a second structure without a fixture holding the second structure; directing the first robotic arm and the second robotic arm based on a second set of coordinates to move the first structure and the second structure such that a protrusion of the first structure or an opening of the second structure is directed to a position where the first structure and the second structure can be joined together, wherein the protrusion does not contact the second structure or the opening does not contact the first structure; joining the first structure and the second structure at the protrusion or the opening; and A computer-readable medium configured to cause

28. 30. The computer readable medium of claim 27, wherein the first structure is joined to the second structure with a first adhesive.

29. A code for curing the first adhesive with a curing device on the second robotic arm.

30. The computer readable medium of claim 28, further comprising:

30. 30. The computer readable medium of claim 28, wherein the first adhesive is cured by exposure to ultraviolet light.

31. Applying the first adhesive to at least one surface of the first structure or the second structure, so that the first structure and the second structure are joined at the at least one surface of the first structure or the second structure to which the first adhesive has been applied; and curing the first adhesive; and 30. The computer readable medium of claim 28, further comprising code for:

32. Applying a second adhesive to at least one surface of at least the joined first and second structures or the third structure; bonding the bonded first and second structures to the third structure at at least one surface of the bonded first and second structures or the third structure to which the second adhesive is applied; curing the second adhesive; and 32. The computer readable medium of claim 31, further comprising code for:

33. 33. The computer readable medium of claim 32, wherein each of the first and second adhesives comprises a fast-curing adhesive, the fast-curing adhesive being cured by exposure to ultraviolet (UV) light.

34. The computer-readable medium of claim 27, wherein instructing at least the first structure or the second structure is based on a move-measure-correct procedure.

35. 35. The computer readable medium of claim 34, wherein the move-measure-correct procedure is based on laser metrology.

36. The computer-readable medium of claim 27, wherein the opening comprises a recess and the protrusion is inserted into the recess.

37. 37. The computer readable medium of claim 36, wherein an adhesive is deposited in the recess of the second structure, and the protrusion of the first structure is bonded to the second structure by the adhesive.

38. 30. The computer readable medium of claim 27, further comprising a cord for joining the first structure and the second structure without contact between the first structure and the second structure.

39. 40. The computer readable medium of claim 38, wherein the first structure and the second structure are joined without contact using an adhesive.

40. 30. The computer readable medium of claim 27, wherein the first robotic arm engages the first structure with an end effector removable from the first robotic arm.

41. 30. The computer readable medium of claim 27, wherein the first robotic arm engages the first structure with an end effector integral with the first robotic arm.

42. 30. The computer-readable medium of claim 27, wherein the first structure has a volume of 500 milliliters or greater.

43. The computer-readable medium of claim 27, wherein the first structure has a weight of 100 grams or more.

44. The computer-readable medium of claim 27, wherein the first structure comprises a portion of a vehicle chassis.

45. The device of claim 1, wherein the protrusion comprises a tongue.

46. ​​The device of claim 1, wherein the opening comprises a groove.

47. The apparatus of claim 46, wherein the groove comprises a lateral bond gap.

48. The apparatus of claim 46, wherein the groove comprises a vertical bond gap.

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