Robotic Assembly of Transportation Structures Using In-Situ Additive Manufacturing

Abstract

To provide a method for flexible in-situ additive manufacturing of components or portions thereof of transportation structures. [Solution] The automated assembly system for transportation structures includes multiple automated constructors 6200 for assembling transportation structures. The assembly system spans a fully vertically integrated manufacturing process from powder production to recycling. At least some of the multiple automated constructors 6200 can move between stations 6100 in an automated manner under the guidance of a control system. A first automated constructor 6200 of the multiple automated constructors 6200 includes a 3-D printer that prints at least some of the components and then moves the components to a second automated constructor 6200 of the multiple automated constructors 6200 for installation during assembly of the transportation structure. The automated constructors 6200 utilize sensors to enable machine learning to perform a wide variety of tasks.

Description

Technical Field

[0001] Cross - Reference to Related Applications This patent application claims priority to U.S. Non - Provisional Application No. 15 / 604,037, filed May 24, 2017, entitled "ROBOTIC ASSEMBLY OF TRANSPORT STRUCTURES USING ON - SITE ADDITIVE MANUFACTURING", which has been assigned to the assignee of this application and is hereby incorporated by reference in its entirety.

[0002] The present disclosure generally relates to manufacturing, and more particularly to flexible automated assembly techniques for manufacturing vehicles, aircraft, boats, and other transport structures using 3 - D printing.

Background Art

[0003] Conventional manufacturing facilities may include a significantly inflexible factory infrastructure for mass - producing products. For example, a factory may use a fixed robotic assembly system operating on an assembly line to achieve efficient mass production. The inflexible factory infrastructure often limits the manufacturing system to producing only a few models of transport structures such as vehicles, motorcycles, boats, aircraft, etc., and even then, it may be expensive to manufacture each model of the transport structure. If a factory is permanently or long - term configured to produce one or more unprofitable models, the factory may face financial difficulties due to the amortization costs of the factory and machine tools and may fall into deficit operation. More specifically, in that case, due to the lack of flexibility in the factory, the need to amortize the machine tools before changing the factory's resources from manufacturing unprofitable products to manufacturing new or more commercially successful existing products, and other constraints, the factory may not be fully utilized.

[0004] Furthermore, when additive manufacturing (AM) technology may be desirable for three-dimensional (3-D) printing of components or parts of components of a transport structure, such a factory has conventionally outsourced the AM function or, if the AM function is in-house, the AM is carried out in a dedicated location separate from the assembly line of the transport structure. Thus, those factories have little, if any, flexibility to change the AM capabilities to adapt to changing circumstances. SUMMARY OF THE INVENTION

[0005] In the following, multiple aspects of a system and method for 3-D printing of components of a transport structure are described in more detail.

[0006] One aspect of an automated assembly system for a transport structure includes a plurality of automated constructors for assembling the transport structure, wherein a first automated constructor of the plurality of automated constructors includes a three-dimensional (3-D) printer for printing at least a portion of a component and moving this component to a second automated constructor of the plurality of automated constructors for attachment during the assembly of the transport structure.

[0007] One aspect of a method for automated assembly of a transport structure by a plurality of automated constructors, wherein a first automated constructor of the plurality of automated constructors is equipped with a three-dimensional (3-D) printer, includes printing at least a portion of a component of the transport structure by the 3-D printer, automatically moving this component from a first automated constructor of the plurality of automated constructors to a second automated constructor of the plurality of automated constructors, and automatically attaching this component by the second automated constructor of the plurality of automated constructors during the assembly of the transport structure.

[0008] Other aspects of systems and methods for 3-D printing components of a transport structure will become readily apparent to those skilled in the art from the following detailed description, which shows and describes a plurality of embodiments by way of example only. As will be understood by those skilled in the art, the facilities and methods for manufacturing the transport structures described herein can all be other different embodiments without departing from the present invention, and the plurality of details thereof can be changed in various other respects. Accordingly, the drawings and the detailed description are to be regarded as illustrative in nature and not as restrictive.

[0009] Here, various aspects of flexible modular robotic manufacturing of a transport structure are presented in the following attached drawings and in the detailed description by way of example and not limitation.

Brief Description of the Drawings

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Best Mode for Carrying Out the Invention

[0011] The detailed description set forth below in connection with the accompanying drawings is intended to provide an explanation of various embodiments of 3-D printing of components of a transport structure, and is not intended to represent only those embodiments in which the present invention may be practiced. The term "exemplary" as used throughout this disclosure means "serving as an example, instance, or illustration," and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that will fully convey the scope of the present invention to those skilled in the art. However, the present invention may be practiced without those specific details. In some cases, well-known structures and components may be shown in block diagram form or may be omitted entirely in order to prevent obscuring the various concepts presented throughout this disclosure.

[0012] There is a need for flexible modular robotic vehicle manufacturing facilities, systems, and methods. The facilities, systems, and methods provided herein enable the manufacture and assembly of flexible modular transport structures. The facilities, systems, and methods may include a plurality of variable robotic assembly stations for performing a set of one or more vehicle manufacturing processes, and a plurality of variable robots such as an automated constructor for performing one or more vehicle manufacturing processes. Flexibility in vehicle manufacturing and assembly can be provided in (1) the variability of the position and / or area of the robotic assembly stations, (2) the ability of robots such as an automated constructor to perform one or more vehicle manufacturing processes with easy automated reconfiguration between each process, and (3) the customization of vehicle parts including connectors and interconnecting materials using 3-D printing or other techniques. The automated processes enable the construction and assembly of parts, the tracking of parts during assembly and throughout the useful life of the parts, and the MAC and flexible construction of various types of vehicles.

[0013] In many cases, for illustrative purposes, vehicle manufacturing and related facilities are referenced, but it will be understood that the techniques described in this disclosure are equally applicable to and suitable for other types of transport structures including, but not limited to, boats, airplanes, helicopters, motorcycles, trains, buses, and the like.

[0014] This specification provides a flexible modular vehicle manufacturing facility, system, and method for the manufacture and assembly of transportation structures. The manufacturing facility, system, and method provided herein need not be specific to a design and may be capable of accommodating a wide variety of vehicles and demands. The facility may include one or more robotic assembly stations. Each robotic assembly station may include one or more robots including an automated constructor. A set of vehicle manufacturing processes may be performed at each robotic assembly station. The facility may use a combination of 3-D printed parts and commercial off-the-shelf (COTS) parts. Flexibility in vehicle manufacture and assembly may be provided in (1) the variability of the location and / or area of the robotic assembly stations, (2) the ability of robots such as automated constructors to perform one or more vehicle manufacturing processes with easy automated reconfiguration between each process, and / or (3) in-place printing using 3-D printing to facilitate assembly including connectors and interconnecting materials.

[0015] Improvements in flexibility and non - design - specific capabilities in manufacturing facilities can provide significant economic benefits. For example, traditional manufacturing systems may build highly inflexible factory infrastructures to mass - produce products. In the case of automobile manufacturing, a factory of a certain scale may be used to assemble vehicles. However, even smaller factories without stamping facilities and painting factories without stamping factories can cost hundreds of millions of dollars to build, equip, and maintain. In many cases, the resulting factories can support only a few vehicle models and / or vehicle types, and the cost of manufacturing each of those vehicle models and / or vehicle types can easily exceed $100 million. For a large, inflexible factory that can build only a specific vehicle to be profitable, that specific vehicle must utilize a significant portion of the factory's capacity. If a factory is configured without the flexibility to manufacture one or more unprofitable vehicles, the factory may not be able to replace one or more unprofitable vehicles with another vehicle model due to the costs associated with specific machine tools, fixture updates, and programming (e.g., fixed spot - welding robots) for assembling the conventional body structure. Replacing an unprofitable model before the machine tool's depreciation is complete can be a financial burden.

[0016] Accordingly, in various embodiments, the facility can have features not specific to the design to provide for variability in the location and / or area of the robotic assembly stations, described above and further described below, the ability of robots such as automated constructors to perform one or more vehicle manufacturing processes with easy-to-use automation between processes, and / or flexibility such as the customization of vehicle parts including connectors and interconnecting materials using 3-D printing. Unlike conventional mass production factories, a flexible facility can be easily reconfigured via an automated system, including robots enabled with machine learning to reconfigure themselves as needed to manufacture different vehicles, without incurring downtime for retooling or reprogramming the facility. Further, a 3-D printer can be supported on a robotic device, and in some embodiments, the robotic device can move to different assembly stations as needed to 3-D print different parts or components dynamically and substantially in real time. Printed parts can be further manipulated or moved by the supporting robotic device or by one of any number of automated constructors. For example, a robot can receive a 3-D printed part at an assembly station and place the part on a transport structure or insert the printed part into another component for assembly and integration with the components.

[0017] FIG. 1A shows a vehicle manufacturing facility having a plurality of robotic assembly stations and a plurality of automated constructors. Vehicle manufacturing facility 1000 can include one or more robotic assembly stations, such as a first robotic assembly station 1010a, a second robotic assembly station 1010b, a third robotic assembly station 1010c, a fourth robotic assembly station 1010d, etc. The robotic assembly stations can include a designated area at a designated location where a set of one or more vehicle manufacturing processes occur.

[0018] The vehicle manufacturing process may include any process related to the manufacture of a vehicle, such as, among many processes, the manufacture, printing, painting, assembly, disassembly, cutting, bending, stamping, forming, machining, processing, treatment, melting, heating, cooling, cleaning, recycling, disposal, painting, inspection, imaging, and / or testing of parts, components, and / or assemblies of parts or components of the vehicle. One or more types of vehicle manufacturing processes may occur at various stages during the manufacture and / or disassembly of the vehicle.

[0019] For example, the assembly of a vehicle may include a step of putting the vehicle, but a disassembly step of disassembling vehicle parts may be desirable when a used vehicle is recycled. Disassembly may also occur when the chassis or the three-dimensional framework is disassembled to form a chassis having a different shape.

[0020] Additively manufactured parts may be 3-D printed and thereby customized for a specific application, but additively manufactured parts may further undergo additional steps such as painting, cutting, bending, or other operations, depending on the application, for example, to accommodate a mismatch in fitting or to adjust for tolerance. In addition, COTS parts or custom parts manufactured in an assembly plant may include any of the above steps, including painting, cutting, bending, stamping, etc. One or more interfaces between parts may be heat treated, and sub-components may require adhesion or heat melting. During the recycling process, melting may be used for the extraction of metal from the material for atomization into powder and for final use by an additive manufacturing device.

[0021] To finish a commercial transport structure, parts may be cleaned, imaged, inspected, and tested in other ways.

[0022] Each of the foregoing steps may be performed, in whole or in part, at one or more stations by one or more of a plurality of automated constructors. In some example embodiments, each station includes a designated area for performing one of the above operations exclusively, and the automated constructor moves to the station as needed or otherwise exists at the station. For example, an automated constructor tasked with inspecting parts can move to the station to perform the inspection. The automated constructor can inspect, on the fly, the tolerances of the assembled parts to ensure that the parts meet one or more specifications. If a part is not within the specification range, the automated constructor can communicate this information to a central controller or another automated constructor, and if the part cannot be corrected to fall within the specification range through available corrective measures, or if the problem is inherently critical, the part can be removed from the ongoing assembly.

[0023] In some cases, a vehicle manufacturing process may be independent of other vehicle manufacturing processes. For example, a vehicle manufacturing process may occur independently, regardless of other processes being executed or having been executed.

[0024] In other examples, a vehicle manufacturing process may be dependent on other vehicle manufacturing processes. For example, two or more vehicle manufacturing processes (e.g., heating and washing) may occur simultaneously. In another example, two or more vehicle manufacturing processes (e.g., cooling after heating) may be performed sequentially and continuously. The processes may occur in a specific order (e.g., step A occurs before step B), or may occur sequentially without regard to order (e.g., step A before step B or step B before step A may both be possible). In some cases, two or more vehicle manufacturing processes may occur within a specific time frame. This time frame may be a predefined period.

[0025] One or more vehicle manufacturing processes may be grouped into a set. Optionally, a vehicle may be partially or fully assembled by undergoing one or more sets of one or more vehicle manufacturing processes. For example, a vehicle may be partially or fully assembled by undergoing one or more sets of one or more vehicle manufacturing processes in a particular order. Optionally, a vehicle may be partially or fully assembled regardless of order. Alternatively or additionally, a vehicle may be intentionally partially or fully disassembled by undergoing one or more sets of one or more vehicle manufacturing processes in a particular order. Optionally, a vehicle may be partially or fully disassembled regardless of order.

[0026] One or more sets of vehicle manufacturing processes may be performed at each robotic assembly station. Each robotic assembly station may perform different sets of one or more vehicle manufacturing processes. For example, even if one or more manufacturing processes are the same between stations (e.g., a first set of processes shares the same process with a second set of processes), there may be one or more additional manufacturing processes that are different between stations. Alternatively, two or more robotic assembly stations may perform the same set of one or more vehicle manufacturing processes. Optionally, a single vehicle manufacturing process may be performed at one robotic assembly station. Optionally, multiple vehicle manufacturing processes may be performed at a single robotic assembly station. Optionally, a single vehicle manufacturing process (e.g., melting) may be performed across two or more robotic assembly stations.

[0027] The vehicle manufacturing facility 1000 may include a single building or multiple buildings. The vehicle manufacturing facility may be integrated into a building used to perform one or more additional features. The vehicle manufacturing facility may be or include one or more factories, plants, warehouses, hangars, or any other type of structure. The vehicle manufacturing facility may be or include a site that includes one or more structures. The vehicle manufacturing facility may include one or more roofs and / or one or more walls. Optionally, the vehicle manufacturing facility may be outdoors without the need for a roof and / or walls. The vehicle manufacturing facility or the structures included therein may include one or more vertical levels (e.g., floors), and each level may be located at, above, or below the ground surface. The vehicle manufacturing facility may have an open layout (e.g., without partitions or rooms), or may include one or more rooms or partitions. The description of the facility herein may apply to any combination of the structures or layouts described herein.

[0028] The vehicle manufacturing facility 1000 may include the number or desired number of robotic assembly stations necessary to perform one or more sets of vehicle manufacturing processes within the facility. The description of the robotic assembly stations herein may apply to stations that perform any of the processes described herein, which may include assembly processes and / or disassembly processes. The vehicle manufacturing facility may include any number of robotic assembly stations. In some cases, the number of stations may be increased or decreased to accommodate the limited volume and space of the facility. The stations may be distributed across any type of facility structure or layout described herein. For example, the stations may all be located within the same building, or may be distributed across multiple buildings. The stations may be located within a site or on land that includes one or more buildings. The stations may be included as part of a building that may have any additional areas assigned to other functions or activities.

[0029] A station may encompass the area of a facility. The areas of multiple stations may or may not overlap. Two or more stations may be adjacent to each other. A station may have a fixed size, position, and / or shape. In some cases, the boundary of a station may be imposed by a physical entity such as a partition, wall, boundary, geographical fence, division, or other object. In some cases, the boundary of a station may be indicated by a visible marker such as a drawing (e.g., a line), label, lighting (e.g., brightness, color, type of lighting, etc.), or any other form of marking. Alternatively, the boundary of a station may not be explicitly divided by physical markers and / or visible markers. Alternatively, a station may vary in size (e.g., increase or decrease), position, shape, or any other characteristic. Such variations may occur over time. Such variations may be provided in response to new or changing demands. For example, in response to an increase in demand, the size of a robotic assembly station may increase. Further, in order to meet the increased demand, the functionality of one or more robotic assembly stations may be changed. Similarly, in response to a decrease in demand, the size of a robotic assembly cell may decrease. In response to the decreased demand, the functionality of one or more robotic assembly stations may be changed. A station may or may not include a work area. The work area may include a platform or area where vehicles, vehicle parts, and / or vehicle assemblies may be placed for work. For example, a work-in-progress assembly may be placed in the work area within the station area. The work area may be fixed or moving. For example, the work area may be an autonomous assembly platform. In another example, the work area may be a conveyor belt or other moving platform. The work area may vary in size, position, shape, or other characteristics in response to changes in the composition of the station and / or the functionality of the station (e.g., the set of processes performed by the station).The working area of the station may be specific to the station (e.g., not overlapping with another station). In some embodiments, the working area may be accessible only to the components of the station (e.g., robots associated with the station). The station may include other areas such as sub-stations (e.g., arm exchange stations, supply stations, etc.) and paths (e.g., the movement paths of robots, the transport paths of vehicle parts or vehicle assemblies, etc.).

[0030] Each robotic assembly station may include one or more robots, such as an automatic constructor 1020, configured to perform a set of one or more vehicle manufacturing processes. The automatic constructor may be referred to as a robot, a robotic device, an automated machine, an automated device, an automated apparatus, an automotive tool, or a manufacturing instrument. The automatic constructor may perform assembly steps or disassembly steps. The automatic constructor may perform any of the manufacturing processes described elsewhere in this specification, either alone or in combination with one or more additional automatic constructors. For example, the automatic constructor may be configured to receive instructions regarding performing a set of one or more vehicle manufacturing processes, and may then be further configured to execute the received instructions. The automatic constructor may include instructions pre-programmed to perform one or more vehicle manufacturing processes. Alternatively or additionally, the automatic constructor may receive real-time instructions for performing one or more vehicle manufacturing processes.

[0031] The automated constructor may be able to perform a single vehicle manufacturing process (e.g., bending) within a set of vehicle manufacturing processes. For example, within a robotic assembly station, a first automated constructor may perform a bending process and a second automated constructor may perform a cutting process. Alternatively, the automated constructor may be able to perform two or more vehicle manufacturing processes (e.g., bending, cutting, etc.) within a set of vehicle manufacturing processes. For example, within a robotic assembly station, a first automated constructor may perform both a bending vehicle manufacturing process and a cutting vehicle manufacturing process, and a second automated constructor may perform both a heating vehicle manufacturing process and an adhesive injection vehicle manufacturing process. A single automated constructor may perform a single manufacturing process, a single automated constructor may perform multiple manufacturing processes, multiple automated constructors may collectively perform a single manufacturing process, or multiple automated constructors may collectively perform multiple manufacturing processes.

[0032] In some cases, the automated constructor may be reconfigured to perform different functions. The different functions may be associated with one or more vehicle manufacturing processes that the automated constructor is instructed to perform. The reconfiguration may be a hardware reconfiguration or a software reconfiguration. For example, the automated constructor may be exchangeable between the end effectors of different robots that are equipped with different tools required to perform different functions. In another example, the automated constructor may be reprogrammable, such as to execute different instructions. In one exemplary embodiment, the automated constructor learns through machine learning a new operation or a different operation, or a variation or improvement of an existing operation. Machine learning can be autonomous in the sense that the algorithm that executes the machine learning process is included in a processing system, such as one or more processors coupled to a memory or other storage medium that is present within the automated constructor. In other embodiments, the processing system within the automated constructor communicates with one or more other robots, automated constructors, a central control system, or control facilities to perform machine learning functions and prioritize. In other exemplary embodiments, machine learning can be independent of and cooperative with respect to a particular operation. The robot can perform the process with the intended results in similar parts of the new product by creating the parts during the previous construction. This activity of the robot may include machine learning.

[0033] Machine learning can include a number of applications in connection with the manufacture of transportation structures. An automated constructor, for example, may be programmed using algorithms so as to be able to make predictions based on previously stored data or so as to be able to make decisions based on previous experience. For this purpose, machine learning represents a deviation from or more generally an addition to the use of static programs, in which an automated constructor is programmed to perform one or more operations without the dynamic changes that may otherwise improve the work or make it more efficient.

[0034] One example of machine learning may involve an automated constructor that has an operation of attaching a component to a transportation structure after removing the component from an automated constructor incorporating a 3-D printing function using one or more robotic arms or effectors. This component may include, by way of example, a transmission part, a gear case, a heat exchanger, a power train, etc., or sub-components of any of these. Depending on the particular component to be attached, after acquiring the first experience of attaching the component (e.g., by being first directed by steps determined via a static program), the automated constructor may learn one or more ways to mobilize itself more efficiently and may determine the position or angle of the component for obtaining an optimal arrangement within the vehicle.

[0035] Those examples of machine learning and similar examples may help to take into account the environment and facilities in which an automated constructor operates.

[0036] When tightening components to a vehicle is also performed, the automated constructor may learn in real time, via a machine learning algorithm, an optimal way to tighten the components, such as attaching the screws of other fasteners in a particular order that best secures or most quickly secures the components.

[0037] As another example, machine learning may include an automated constructor having the purpose of modifying COTS components in a specific way using one or more effectors. Each time, the automated constructor may use the default specifications to modify the COTS components and achieve the same final result, but the automated constructor may adopt machine learning and learn to use tools in a specific order, or learn to optimize the modification process through ongoing experience by using tools of different sizes, etc., so as to determine the fastest, most efficient, and most effective method for performing the modification through experience.

[0038] A cluster or group of automated constructors, such as robots, may be configured (e.g., using different combinations of algorithms) to work together to achieve faster results on an assembly line, optimize additive manufacturing by distributing AM operations in a more productive way, or execute using different robots for different functions. For example, through the learning experience of one or more 3-D printing robots, it may be determined that it is more efficient and faster for a group of 3-D printing robots to print each different sub-component of a gear case at a station, rather than each 3-D robot in the group of 3-D robots working on different sub-components of different components (such as gear cases, crankshafts, accelerator pedals, suspensions, etc.), or vice versa.

[0039] Machine learning among automated constructors may be used to dynamically determine any number of different priorities according to a set of conditions observed in real time. A robot may recognize that at times certain tasks require more attention than others and that at other times the opposite may be true. For example, a group of automated constructors may recognize through machine learning that a particular station has become (or is predicted to become) a bottleneck based on the automated constructor's predictions. Based on this recognition, more automated constructors may change their behavior and temporarily move to the problematic station to resolve the bottleneck.

[0040] As another example, machine learning may be as fundamental as one or more automated constructors learning an entirely new and different task. A robot initially programmed to weld may then learn to apply an adhesive. An automated constructor that includes a 3-D printer may then learn to position itself in or point itself in the direction of an area proximate to a vehicle, and the parts printed by the 3-D printer can be easily passed to another automated constructor for faster placement of the parts.

[0041] In another example embodiment, automated constructors located at various robotic assembly stations can dynamically employ self-learning techniques to avoid collisions with other automated constructors or any other obstacles, including collisions with employees working in cooperation with or independently of nearby automated constructors at the assembly station.

[0042] Other examples regarding the use of machine learning are shown below.

[0043] Machine learning for slicing in an additive manufacturing process. As described above, in aspects of the present disclosure, an automated constructor may be configured using the ability to perform an additive manufacturing process. In addition to the manufacturing process, slicing refers to the step in which a computer-aided design (CAD) file of a 3-D printed part is cut (or "sliced") to provide instructions to a printer for printing the part. Those instructions may include G-code that provides a movement pattern for a print head / deflector to execute the print. Often, those movement patterns are inefficient, resulting in a slow print speed. A machine learning algorithm can be incorporated into the slicing program to provide an efficient movement pattern to the print head / depositor. The aforementioned algorithm optimizes the path selected by the print head / depositor, enabling a faster and higher quality build.

[0044] Machine learning for motion control of a print head. Machine learning may enable the print head to move along optimized paths and at optimized speeds. Instead of simply moving from point A to point B, a machine learning algorithm can determine the fastest and most efficient path. This optimization process can accelerate the print head while printing regions with simple shapes and decelerate it taking into account changes in direction. Machine learning can provide more flexible motion control firmware by optimizing the G-code path to allow for more extreme movements.

[0045] Machine learning for material development. Machine learning may be used to print parts accurately and / or print on-the-fly on parts. For example, if lightweight parts are required, machine learning can guide the automated constructor to print using aluminum. In situations where high-strength components are needed, the constructor can print using steel. Additionally, machine learning can accurately determine alloy mixtures as needed, thereby driving the development of alloys based on loads and other considerations (environmental factors, density, position on the vehicle, etc.).

[0046] Machine learning for structural optimization. During the printing process, machine learning algorithms can automatically generate a filling structure within areas where structural reinforcement is required. Additionally, these algorithms can be configured to "predict" the structure within the area by observing the construction stage and instruct the automated constructor to print. Before the vehicle is manufactured, various load cases are specified and become part of the specification, thereby providing the machine learning algorithm with a database to reference for accurately printing the required amount of structure. Machine learning may be integrated into the CAD design stage itself, with the algorithm predicting possible structures and automatically including them. This algorithm is similar to the autocomplete algorithm of an internet search bar.

[0047] Machine learning during vehicle assembly. In other embodiments, machine learning algorithms can enable the automated constructor to obtain the necessary tools when needed, as required. For example, during an assembly process where nuts or bolts need to be tightened to a specified torque, the constructor can identify the situation and automatically extend an effector with a torque wrench. Machine learning also enables those constructors to automatically reposition themselves based on the assembly stage, thereby optimizing the layout of the plant. Tools and parts are supplied just-in-time.

[0048] In short, depending on the configuration and embodiment in question, there may be a wide variety of applications of machine learning processes that may be applicable to the present disclosure. It will be understood that the design of such algorithms to facilitate machine learning may be within the scope of understanding of those skilled in the art who have studied the present disclosure (regardless of the source, such as the automatic constructor itself or a central control location that is subsequently sent to the automatic constructor). General non-exhaustive examples of machine learning algorithms that may be applicable may include decision tree learning algorithms, linear regression and logistic regression, classifiers, and support vector machine algorithms. From more general algorithms such as those described above, more complex algorithms or groups of algorithms may be developed by those skilled in the art who combine logic, experience, and prediction with movement and operation.

[0049] In addition to algorithms, the automatic constructor may employ a plurality of machine learning sensors to collect data related to the machine learning process and to perform other functions. For example, the automatic constructor may include low-power sensor nodes configured to collect various types of data that may be used in the application of machine learning. The collected data may be transmitted, for example, via a wireless connection, to a processing system within the automatic constructor or a central control facility for further processing and / or routing to other automatic constructors. Sensors may include, for example, optical sensors, thermal sensors for detecting temperature, sensors for detecting the presence of charge or voltage, acoustic sensors, sensors for detecting chemical substances near the automatic constructor (including chemical substances that may be harmful to the vehicle, nearby components, the environment, or others), and the like. The sensors may also include RF sensors, wireless sensors, and other electrical sensors for receiving radio electrical signals or messages.

[0050] The automatic constructor may be configured to move between and within a robotic assembly station. The robotic assembly station may include any number of automatic constructors necessary to perform a set of one or more vehicle manufacturing processes associated with the robotic assembly station. For example, depending on the embodiment, the robotic assembly station may include about 1 to 1000 or more automatic constructors. In other embodiments, each robotic assembly station may include any number of automatic constructors. For example, each robotic assembly station may or may not include the same number or same type of automatic constructors. The number and / or type of automatic constructors within each robotic station may be selected independently of other robotic stations. The automatic constructor may be associated with one or more robotic assembly stations. For example, the automatic constructor may be associated with only the first robotic assembly station 1010a. In another example, the automatic constructor may be associated with both the first robotic assembly station 1010a and the second robotic assembly station 1010b. In some cases, the automatic constructor may be associated with one or more robotic assembly stations when the automatic constructor is within the area of the robotic assembly station and / or when the automatic constructor is performing a manufacturing process associated with the robotic assembly station. For example, if the robotic assembly station is associated with the assembly of a chassis part, the automatic constructor may assist in the assembly of the chassis part. The association of the automatic constructor may vary based on requirements. For example, in the first robotic assembly station, if there is a greater need for an automatic constructor, the automatic constructor may be associated with the first robotic assembly station. If the need increases in the second robotic assembly station and decreases in the first robotic assembly station, the automatic constructor may be associated with the second assembly station.An automatic constructor may be associated with only one station at a time. Alternatively, an automatic constructor may be associated with multiple stations at a time. In some cases, an automatic constructor may not be associated with any station at a particular point in time. For example, one or more "extra" automatic constructors may be in an idle state or waiting until they are associated with a robotic assembly station. For example, the automatic constructor 1020 may be in an idle state until, for example, a control system or another automatic constructor 1020 provides an instruction to be mobilized to a robotic assembly station and execute an assigned task.

[0051] In some cases, an automatic constructor may traverse different areas of a manufacturing facility as needed. For example, as shown in FIG. 1A, the automatic constructor 1020 may move from the first robotic assembly station 1010a to the second robotic assembly station 1010b. The automatic constructor may execute a manufacturing process associated with the first robotic assembly station while it is within the first robotic assembly station. The automatic constructor may execute a manufacturing process associated with the second robotic assembly station when it moves to the second robotic assembly station. In some cases, the automatic constructor 1020 may leave the robotic assembly station 1010b. This operation may occur when the automatic constructor is no longer needed at this robotic assembly station or when the need is greater at a different location. In some cases, the automatic constructor 1020 may enter the robotic assembly station 1010c. This operation may occur when the automatic constructor is needed at this robotic assembly station. The automatic constructor may move within the robotic assembly station 1010d.

[0052] In some cases, the designated area and / or designated position of the robot assembly station may change with each position and movement of one or more automated constructors within the assembly station that performs a set of one or more vehicle manufacturing processes. For example, if one or more automated constructors associated with the first robot assembly station 1010a move to the position of the second robot assembly station 1010b, and one or more automated constructors associated with the second robot assembly station move to the position of the fourth robot assembly station 1010d, the position of the first robot assembly station may be changed to the initial position of the second robot assembly station, and the position of the second robot assembly station may be changed to the initial position of the fourth robot assembly station. Two or more robot assembly stations may share the same designated position. Two or more robot assembly stations may partially or completely overlap within the designated area. In other examples, the designated area and / or designated position of the assembly station may change with each size and / or position of the components or assemblies of components of the vehicle that are the subject of a set of one or more vehicle manufacturing processes.

[0053] A vehicle manufacturing facility may include a vehicle transport system that can transport a vehicle, or other transport structures or parts of transport structures, to multiple locations (e.g., robotic assembly stations, etc.) during the assembly process. For example, the transport system can include a moving platform such as a conveyor belt. In some cases, a gantry may be used to transport vehicles or parts. Alternatively or additionally, the transport system can include one or more robots (e.g., automated guided vehicles) programmed to transport partially or fully assembled vehicles or other transport structures or vehicle parts subject to the assembly process. Alternatively or additionally, the transport system can include manual labor by facility employees who, for example, receive an order to transport a vehicle or vehicle parts to multiple locations within the facility. For example, the vehicle transport system can be a combination of a conveyor belt, robots, and / or manual labor (e.g., an employee supplies a tube to an automated guided vehicle at location A, the automated guided vehicle transports the tube from location A to a conveyor belt at location B, and the conveyor belt transports the tube from location B to multiple other locations within the facility). The transport system can transport a vehicle or vehicle parts to different locations within the same robotic assembly station, between different robotic assembly stations, and / or between a robotic assembly station and another location.

[0054] In some cases, during the vehicle assembly process, multiple types of transport structures (e.g., a first aircraft, a second aircraft, a first motorcycle, a second motorcycle, a first automobile model, a second automobile model, a first boat model, a second boat model, a first bus model, a second bus model, etc.) can be transported to one or more robotic assembly stations via the vehicle transport system. Alternatively or additionally, multiple types of vehicle components (e.g., wheels, tubes, engines, etc.) or assemblies of vehicle components can be transported to one or more robotic assembly stations via the vehicle transport system. The facility can simultaneously assemble and / or disassemble multiple vehicles.

[0055] The facility may simultaneously perform the assembly and / or disassembly of multiple types or models of transportation structures. For example, in the case of vehicles, a first vehicle model may traverse various robotic assembly stations within the facility, and each station is located at different positions within the facility at different stages of assembly. Simultaneously and in parallel, a second vehicle model may be traversing various different robotic assembly stations within the facility at different stages of assembly. The first and second vehicle models may traverse the same robotic assembly station and / or different robotic assembly stations. Optionally, the first and second vehicle models may traverse the same robotic assembly station simultaneously or at different times. The facility may simultaneously accommodate the assembly and / or disassembly of any number of vehicles or vehicle models. The differences in the vehicle models (e.g., design) for which assembly and / or disassembly is being performed simultaneously may be significantly different (e.g., constructing boats, cars, and buses simultaneously) or slightly different (e.g., constructing three different series models of the same car brand, each series including the same body design).

[0056] One or more robotic assembly stations may be reconfigured to accommodate the assembly and / or disassembly of different vehicle models. In some cases, different models of the transport structure may be assembled and / or disassembled in multiple batches. For example, one or more robotic assembly stations may be configured to assemble a first vehicle model. After assembling a first batch of the first vehicle model, one or more robotic assembly stations may be reconfigured to assemble a second batch of a second vehicle model. Alternatively or additionally, the robotic assembly stations may be reconfigured as needed (e.g., configured to build one of the first vehicle models, then reconfigured to build one of the second vehicle models, then reconfigured to build one of the third vehicle models, and then reconfigured again to build one of the first vehicle models, etc.). Thus, when different vehicle models or types are assembled sequentially, the robotic assembly stations may be reconfigured as needed. As described above, different vehicle models may arrive in large multiple batches, or may be handled individually or somewhere in between such that each vehicle can be of a different model. The number of vehicles within a series of the same vehicle model or type may vary based on demand. For example, a large batch of 1000 vehicles of the same type may be built using the robotic assembly stations, then a plurality of vehicles of another type may be built using the robotic assembly stations (the robotic assembly stations may optionally need to be reconfigured to accommodate the different vehicle types), and then a medium-sized batch of perhaps a hundred vehicles of another type may be built using the robotic assembly stations (the robotic assembly stations may optionally need to be reconfigured again to accommodate the third vehicle type).

[0057] The functions and / or movements of one or more automated constructors may be controlled by a control system. FIG. 1B schematically shows a control system of a vehicle manufacturing facility. The control system 1500 may include a control server 1505. A server, as the term is used herein, may generally refer to a computer that provides services (e.g., sending and receiving instructions) or resources (e.g., data) via a network connection. The server may be provided or managed by an administrator of the vehicle manufacturing facility (e.g., a plant manager). In some cases, the server may include a web server, an enterprise server, or any other type of computer server, and may be programmed to receive requests (e.g., HTTP or other protocols capable of initiating data transmission) from computing devices (e.g., robots, automated constructors, 3-D printers, etc.) and provide the requested data to the computing devices. Additionally, the server may be a broadcast facility for distributing data, such as a free-to-air broadcast facility, a cable broadcast facility, a satellite broadcast facility, and other broadcast facilities. The server may be a server within a data network (e.g., a cloud computing network). In this specification, the description of the server may apply to one or more servers or other devices that can perform any of the steps described elsewhere in this specification, either individually or collectively. Alternatively or additionally, the system may be implemented using a cloud computing infrastructure or a peer-to-peer configuration. In some example embodiments, the server may be locally present within the assembly facility, or may be present on the premises or in a building of the assembly facility, or may be present in one or more dedicated locations networked to the assembly facility.

[0058] The control server 1505 may include one or more processors, one or more memory devices storing software instructions executed by the processors, and known computing components such as data. The server can include one or more processors and at least one memory for storing program instructions. The one or more processors can be a single microprocessor or multiple microprocessors, field programmable gate arrays (FPGAs), digital signal processors (DSPs), or any suitable combination thereof, or other components capable of executing a particular set of instructions. The computer-readable instructions can be stored on a tangible non-transitory computer-readable medium such as a flexible disk, hard disk, CD-ROM (compact disk-read only memory), MO (magneto-optical), DVD-ROM (digital versatile disk-read only memory), DVD RAM (digital versatile disk-random access memory), or semiconductor memory. Alternatively, the methods disclosed herein can be implemented using hardware components or a combination of hardware and software, such as application specific integrated circuits (ASICs), dedicated computers, or general-purpose computers. Although FIG. 1B shows the control server as a single device 1505, in some embodiments, multiple devices (e.g., computers) may implement the functions associated with the control server.One or more processors may further use any future memory or storage capabilities, to be implemented in the future, including but not limited to storage capabilities that may be essential to the implementation of the Internet of Things (IoT) in addition to cloud storage.

[0059] Network 1515 may be configured to connect and / or provide communication between various components (e.g., one or more automated constructors 1520a - x, other robots, 3 - D printers, other machines, sensors, etc.) and control system 1500. For example, the network may be implemented as the Internet, an intranet, an extranet, a wireless network, a wired network, a local area network (LAN), a wide area network (WAN), Bluetooth®, near field communication (NFC), any other type of network that provides communication between one or more components of the network layout of FIG. 1B, or any combination of these networks. In some embodiments, the network may be implemented using a cellular network and / or a pager network, satellites, licensed wireless, or a combination of licensed and unlicensed wireless. The network may be wireless, wired (e.g., Ethernet®), or a combination thereof.

[0060] The control system 1500 may be implemented as one or more computers that store instructions, which, when executed by one or more processors, generate instructions and send them to one or more automated constructors 1520a - x, and can receive data requests and / or instruction requests from one or more automated constructors. The facility 1000 may include one or more control systems, with each control system operating substantially in parallel with and / or in conjunction with the control system 1500. In some cases, the control server may include a computer on which one or more control systems are implemented. Alternatively, one or more control systems may be implemented on separate computers. The control server may access one or more control systems to execute the control systems and perform one or more steps consistent with the disclosed embodiments. In a particular configuration, one or more control systems may include software stored in a memory accessible by the control server (e.g., a memory local to the control server or a remote memory accessible via a communication link such as a network). Thus, in a particular aspect, one or more control systems may be implemented as one or more computers, as software stored in a memory device accessible by the control server, or as a combination thereof. For example, one control system may be computer hardware, and another control system may be software executable by the control server.

[0061] One or more control systems may be used to control various components of the vehicle manufacturing facility 1000 in a variety of ways, such as by storing and / or executing software that executes one or more algorithms for achieving control. Although multiple control systems for executing one or more algorithms have been described, it should be noted that some or all of the algorithms may be executed using a single control system consistent with the disclosed embodiments.

[0062] One or more control systems may be connected or interconnected to one or more databases 1510. The one or more databases 1510 may be one or more memory devices configured to store data (e.g., sensor data, component manufacturing data, inventory data, etc.). Further, in some example embodiments, the one or more databases may be implemented as a computer system including a storage device. In one aspect, the one or more databases may be used by a control server 1505 to perform one or more operations consistent with the disclosed embodiments. In certain embodiments, the one or more databases may be located at the same location as the control server and / or at the same location as other components (e.g., automated constructors 1520a - x) on the network 1515. For example, an automated constructor 1520 may send sensor data to one or more databases without passing through the control server. Those skilled in the art will recognize that the disclosed embodiments are not limited to the configuration and / or arrangement of the one or more databases.

[0063] The control system 1500 may be configured to generate instructions for one or more automated constructors 1520a - x to move between the respective assembly stations. For example, the control system may instruct one or more automated constructors to autonomously move between the respective assembly stations. The automated constructor may have varying levels of autonomous independence. For example, the control system may enable the automated constructor to move on its own without providing instructions. The automated constructor may have instructions programmed to move on its own, for example, via communication with the control system and / or communication with other automated constructors. In another example, the automated constructor may have pre - programmed conditions or parameters that it must follow while moving on its own. In some cases, the control system may provide periodic or continuous updates to the software within the automated constructor for purposes such as re - defining pre - programmed conditions or parameters, updating learning capabilities (e.g., the ability to move autonomously), or assigning new or different tasks. Alternatively or additionally, the control system may provide more detailed (e.g., step - by - step) instructions for moving between the respective assembly stations to one or more automated constructors. For example, the control system may provide a specific movement path to the automated constructor. In another example, the control system may provide the destination, and the automated constructor may be programmed to reach the destination following any path. The automated constructor may follow one or more parameters in determining the path, or may freely determine the path on - the - fly. In another example, the control system may provide the destination along with parameters such as permitted and non - permitted paths, permitted and non - permitted areas within the facility, preferred paths, preferred areas, and / or time constraints. The automated constructor may reach the destination within the provided range of parameters. The instructions may be pre - programmed within the automated constructor or provided as real - time instructions.The automatic constructor may optionally operate autonomously without pre-planning the route when moving along the route. The constructor may generate the route in real time.

[0064] The automatic constructor may employ machine learning techniques as described in this disclosure to, for example, improve the ability or effect of autonomously moving between assembly stations. For example, the automatic constructor may use one or more sensors to recognize stationary or moving obstacles and record information or parameters regarding any of those obstacles that can assist the automatic constructor in developing future movement routes or in avoiding collisions. The automatic constructor may, in some cases, transmit the information obtained by this machine learning to the control system 1500 depending on factors such as the degree of autonomy of the automatic constructor, which is controlled by its software or hardware capabilities, instructions pre-transmitted from the control system 1500, or other means.

[0065] In some cases, the control system 1500 may change the designated position and / or designated area of the robotic assembly station, such as by instructing the movement of one or more automatic constructors associated with the robotic assembly station. In this way, the robotic assembly station may be flexible and modular, and the vehicle manufacturing facility 1000 may be easily reconfigured by changing the position and / or area of each robotic assembly station within the limits of the facility's location and / or the facility's area. In some cases, the facility may include one or more parts of a building, and in some cases, the facility may include one or more different buildings. One or more robotic assembly stations may be distributed in any layout according to the constraints of the facility's location and / or area. For example, the first robotic assembly station may be arranged in the first building of the facility, and the second robotic assembly station may be arranged in the second building of the facility.

[0066] In some example embodiments, the control system 1500 may generate commands in real time. Some examples of real-time activities include response times of less than one second, less than one-tenth of a second, less than one-hundredth of a second, or less than one millisecond. Each of the robots that includes one or more automatic constructors, as described above or further described below, may be able to respond to commands from the control system in real time or near real time in these embodiments. For example, through the movement of one or more automatic constructors, the robot assembly station may be reconfigured in position and / or area and sized in real time or near real time. In some cases, the control system may generate periodic commands. Periodic commands can be regular or irregular, such as according to a schedule or regular intervals (e.g., every 10 minutes, every hour, every day, every week, etc.). The commands may be provided according to a predefined schedule. The commands may be provided in response to detected events (e.g., the start of the assembly of a new transport structure, the depletion of the raw material supply, the failure of one or more machines, etc.).

[0067] The control system 1500 may be further configured to generate instructions for one or more automated constructors to perform manufacturing processes of a transport structure. In the case of a vehicle, the control system 1500 may be configured to generate instructions for performing one or more vehicle manufacturing processes or one or more sets of one or more vehicle manufacturing processes and / or provide them to one or more automated constructors. For example, the control system 1500 may globally change one or more sets of vehicle manufacturing processes associated with a robotic assembly station. The control system may provide detailed instructions regarding performing vehicle manufacturing processes to one or more automated constructors. For example, the control system may provide specific dimensions of vehicle parts to a 3-D printing automated constructor for printing. Further below, one or more automated constructors that perform one or more vehicle manufacturing processes will be described in more detail.

[0068] FIG. 2 shows a schematic view of a component manufacturing system for a transportation structure. As described above, the details and concepts may be applied to any suitable transportation structure, but FIG. 2 is shown in the context of an exemplary vehicle component manufacturing system. The vehicle manufacturing facility 2000 may use vehicle components manufactured on-site or off-site of the facility. Some vehicle components may first be manufactured off-site and then modified or otherwise processed on-site as needed. Alternatively, some vehicle components may first be manufactured on-site and then modified or processed off-site. In some cases, on-site component manufacturing may include three-dimensional (3-D) printing. In some cases, off-site components may include commercial off-the-shelf (COTS) components. COTS components may be 3-D printed. In some cases, existing components (e.g., 3-D printed COTS, etc.) may be customized via 3-D printing. As used herein, the terms "component" or "vehicle component" may collectively refer to one or more manufacturing tools that can interact with or operate on the components being assembled, in addition to the components assembled in a vehicle or other transportation structure.

[0069] In an example embodiment including a vehicle assembly facility, vehicle parts may be manufactured on-site via 3-D printing. Old vehicles and transport structures, as well as old vehicle parts, may be input into the vehicle part manufacturing system for disassembly within the disassembly area 2100. The old vehicles and old vehicle parts may be unique to this system (e.g., manufactured and / or assembled by the same facility 2000), or may be unrelated to this system (e.g., manufactured and / or assembled by different facilities). The disassembled components of the old vehicles and old vehicle parts may be reused, recycled, or discarded within the metal recycling area 2110. For example, metal parts may be recycled. The recycled metal parts and other printed structural supports may be moved to a blast furnace within the metal recycling area 2110 to produce ingots. Ingots may be produced from metal from any source including sources other than the disassembled old transport structures containing vehicles and old vehicle parts. Other disassembled parts that cannot be reused or recycled may be discarded from the system. The ingots may be supplied to a powder production crucible tower 2120, where they may be converted to metal powder, such as by applying gas spraying or another suitable process to convert the recycled ingots to metal powder. The metal powder output from the powder production crucible tower may be supplied to one or more 3-D printers within the part manufacturing area 2130, and in some embodiments described below, the output powder may be transported directly to one or more 3-D printing robots on the assembly line. The 3-D printers may use metal powder from other sources, such as commercially available metal powder. It will be understood that the 3-D printers are not limited to using metal powder as a raw material for rendering 3-D objects, and that plastics, composite materials, and other materials may be transported directly to the part manufacturing area and / or to the 3-D printing robots and used as materials for 3-D printing one or more components or portions thereof.

[0070] The component manufacturing area 2130 may be equipped with an enterprise resource planning (ERP) system that can instruct one or more 3-D printers to manufacture vehicle parts or finish COTS or other parts. In an example embodiment, the ERP system may include software that enables the facility 2000 to manage and automate a number of functions and manufacturing processes using an integrated software application system. For example, the ERP system can instruct one or more 3-D printers to incorporate required details or changes into the vehicle parts to be printed. The ERP system can include software that automates and integrates core business processes such as manufacturing processes by utilizing large-scale and small-scale data such as customer orders, manufacturing goals, inventory records, parts databases, financial data, and manufacturing schedules. In some cases, the control system 1500 of FIG. 1B may include the ERP system in its software. Alternatively, the ERP system may be a system separate from the control system. In some cases, the 3-D printer may include a stationary machine. Alternatively or additionally, the 3-D printer may include a 3-D printing robot. The 3-D printing robot may be able to move and may be configured to move. The 3-D printing robot may be executed on an assembly line. In some cases, the 3-D printing robot may be an automated constructor associated with one or more robotic assembly stations.

[0071] FIG. 20 shows an exemplary block diagram of an exemplary method for in-situ 3-D printing of components at a robotic assembly station. In the exemplary method, as shown at 2001, a control system may provide instructions to or otherwise communicate with an automated constructor involved in the 3-D printing process. Alternatively, the automated constructor may operate in an autonomous or semi-autonomous manner.

[0072] In some embodiments, the material used for 3-D printing, as shown in step 2005, may include powder sourced from recycled metal, as described above. In other example embodiments, the material to be 3-D printed may include plastic or composite materials and may be obtained from any suitable source. At step 2010, a first automated constructor including a 3-D printer 3-D prints a component or a part thereof. That is, in some embodiments, the 3-D printer is constructed as an integral part of the first automated constructor. In other embodiments, an individual 3-D printer is supported, for example on a platform, by the automated constructor or by using one or more arms or effectors. In example embodiments, the first automated constructor can move between different robotic assembly stations in an automated manner, for example in accordance with real-time commands from a control system, as needed.

[0073] 3-D printing of a part of a component, as described in step 2010, may mean, for example, that the first automated constructor 3-D prints a part of the component onto a non-printed second part of the component, such as a COTS component. Alternatively, the first automated constructor may work in cooperation with another automated constructor, also including a 3-D printer, and each automated constructor may provide a 3-D printed part of the component. As another example, the first automated constructor may 3-D print a part of the component onto a second part of a component that has been 3-D printed, either wholly or in part, previously.

[0074] In example embodiments, as shown in step 2014, the first automated printer may print an interconnect configured to interconnect the component to another structure.

[0075] As a result, in step 2020, the component may be moved from the first automated constructor, which includes a 3-D printer, to the second automated constructor in an automated manner. In an example embodiment, the first automated constructor uses one or more arms and / or an effector at the distal end of the arm to move the 3-D printed component (or a portion thereof) to the second automated constructor, and the function of the second automated constructor is to move the component to a nearby position for attachment and / or to free the first automated constructor to perform other printing operations. In another example embodiment, the second automated constructor grips or otherwise engages the 3-D printed component using a robotic arm and / or effector and releases the component from the first automated constructor. In other embodiments, two or more automated constructors may be used to perform this operation. During these steps, as shown in step 2025, one or more of the first or second automated constructors may exchange robotic arms and / or effectors to obtain the robotic arms and / or effectors necessary to perform the required operations using the 3-D printed component.

[0076] As a result, as shown in step 2030, the second automated constructor (either alone or assisted by other machines, robots, or automated constructors) attaches the component to the appropriate position in an automated manner during the assembly of the transport structure. For example, the second automated constructor uses its capabilities to place the component within the transport structure for attachment.

[0077] The above-described component manufacturing process and the processes further described below may be clearly performed at one or more robotic assembly stations. For example, disassembly may occur at a first robotic assembly station (e.g., robotic assembly station 1010a of FIG. 1), melting of the disassembled components into an ingot may occur at a second robotic assembly station, gas spraying of the ingot into metal powder may occur at a third robotic assembly station, and 3-D printing may occur at a fourth robotic assembly station. Alternatively, one process (e.g., 3-D printing) may occur at two or more robotic assembly stations (e.g., three stations). Alternatively, two or more processes (e.g., disassembly and melting) may occur at the same robotic assembly station.

[0078] A 3D-printed part may be machined simultaneously at a predetermined location, such as on an assembly line, while the part being 3D-printed is being printed by one or more 3D printers, such as a 3D printing robot. Alternatively, the 3D-printed part may have post-print processing performed at a subsequent automated stage in a post-print processing system. The post-print processing system may comprise one or more computer numeric control (CNC) machines configured to perform an automated repeatable surface treatment of the 3D-printed part. For example, the CNC machine may comprise a head for shot-peening that enables an automated repeatable surface treatment. Shot-peening is a process of shaping a metal or composite material by causing a stream of fired metal to impinge. Further painting, cutting, and / or bending may be performed on the 3D-printed part. For example, the system may comprise a painting machine for painting, a bending machine for bending, and a cutting machine (e.g., laser, water jet) for cutting or trimming. The post-print processing system may be configured to hold and immobilize a substrate or other additional element (e.g., attachment location) of the 3D-printed part being processed to fix the part during processing.

[0079] In some cases, the powder or other unwanted material (e.g., particles) of the 3-D printed part can be removed before application of an independent machining step (e.g., surface treatment). For example, the 3-D printed part can be moved to an automatic cleaning station (e.g., within another robotic assembly station) to remove powder or other unwanted particles from the part. The automatic cleaning station may comprise a vibration system, a vacuum system, a combination of a vibration system and a vacuum system, or other techniques for removing material from the printed part. The post-print processing system may further comprise an oven for heat treatment of the 3-D printed part. In some cases, heating and cleaning can be performed simultaneously on the printed part. A heat profile of the heat treatment process, including information regarding the required processing and finishing steps of the printed part, can be determined and controlled by a control system (e.g., a main control system, an ERP system, etc.). Referring again to FIG. 2, after the printed part is machined, the printed part can be moved to various subsystem construction lines 2400, such as the chassis construction line 2300.

[0080] 3D printing technology for component manufacturing can achieve flexibility in many ways. For example, different components may be printed as needed, when required, in response to requests. This advantageously reduces the time to obtain components (e.g., shipped and delivered from another source), reduces inventory space (e.g., storage of components that may be used later), and can increase the monitoring of accuracy and precision during printing. Furthermore, there is a great degree of freedom in customizing components, and this freedom is limited only by the ever-increasing limits on what a 3D printer can print. This advantageously allows for assembling or disassembling various vehicle models without the need for infrastructure changes or other long-term changes in the facility. Additionally, the 3D printer may be supported on a robotic device and may be movable to different assembly stations as needed. In one example embodiment, the control system 1500 may generate instructions for the robotic device to autonomously move to another assembly station or other location. In other example embodiments, the 3D printer may be moved to another assembly station by or with the assistance of one or more additional automated constructors or mobile supply vehicles.

[0081] In another aspect, the vehicle manufacturing facility 2000 may use commercial off-the-shelf (COTS) parts. COTS parts may include standard COTS parts for use in assembly and structural COTS parts for use in constructing complex structures (e.g., chassis). COTS parts may be manufactured on-site, such as in a COTS manufacturing subsystem 2800, or may be obtained from off-site sources. For example, COTS parts that require some form of customization may be manufactured on-site. Optionally, existing COTS parts may be customized or modified using 3-D printing technology or standard machining techniques. In some cases, COTS parts can be both standard COTS parts and structural COTS parts. Structural COTS parts can be used when received. Alternatively or additionally, structural COTS parts can be adapted (e.g., using machine tools) or customized for use in complex structures. Structural COTS parts can be obtained at low cost based on mass production (e.g., bulk) of each manufacturing system. With certain exceptions, structural COTS parts can require little or no machine tools and can be incorporated into assemblies or complex structures with little or no machine tool depreciation. For example, structural COTS parts may include honeycomb or other structured panels containing materials such as carbon fiber, glass fiber, and aluminum, and optionally may include a foam core. Structural COTS parts may include tubes having any cross-section that can include materials such as carbon fiber, aluminum, titanium, glass fiber, plastic, steel, and any combination of these or other materials. Structural COTS parts may include protrusions. Protrusions may require small machine tools for cross-section changes or modifications. Molds for protrusions can be saved for subsequent manufacturing of transport structures. In some cases, a catalog of all tools and fixtures created or received can be stored in a component manufacturing system database, which in some embodiments may be included in database 1510 (FIG. 1B).A vehicle optimization system (e.g., an ERP system, a control system) may be able to access a component manufacturing system / database in order to adjust and optimize the vehicle manufacturing process. For example, the vehicle optimization system may prevent redundant purchases or the manufacture of existing tools (e.g., protruding molds).

[0082] COTS components may optionally be received in the COTS components and receiving area 2209. Whether the COTS components are received by the system in area 2200 or, alternatively, after being mass-produced on-site (e.g., in the COTS manufacturing area 2800), those COTS components can be moved to the bending area 2210 and / or the cutting area 2220. The COTS components can be bent or cut in any order, for example, being efficient and / or feasible for the desired component design. For example, the COTS components can first be moved to the bending area and then to the cutting area. Alternatively, the COTS components can first be moved to the cutting area and then to the bending area. Alternatively, the COTS components can first be moved to the cutting area, then to the bending area, and then again to the cutting area. In some cases, the cutting area and the bending area can each include a robotic assembly station. The bending area may include an automatic bending machine configured to bend the COTS components into the desired shape. The bending may be performed on multiple axes. The cutting area may include a laser and water jet system configured to cut the COTS components. The COTS components can be cut in three dimensions. Any position of the COTS components, including positions other than the ends, can be cut. For example, in the cutting area, a protrusion with the required fillet at one end can be shortened to the correct length, and a part of the cross-section in the central part can be reduced for spacing and weight reduction at a position where the shear load is not so large in a particular design. In some cases, cutting and / or bending may be performed on the assembly line, for example, when it is necessary to perform bending or cutting at the position of the vehicle.

[0083] In addition to the structural COTS parts, the facility 2000 may use standard COTS parts that can be used as part of the final product assembly. Examples of standard COTS parts include transmissions, steering racks, and tires. The structural COTS parts can be used when received in the assembly. For example, standard COTS parts such as tires can be purchased and directly attached to the vehicle wheels without modification. Alternatively or additionally, the standard COTS parts can be adapted or changed before being incorporated. For example, the COTS parts and the standard COTS parts of the transmission provided to the COTS parts and receiving area 2209 by the main primary manufacturer (tier 1 manufacturer) of the automotive transmission can be moved to the laser cutting area 2220, where the existing attachment positions are cut, as shown in FIG. 21, and then moved to the component manufacturing area 2130, where new attachment positions are printed by a robot with 3D printing enabled. Alternatively, a robot with 3D printing enabled (e.g., an automated constructor that supports a 3D printer or has a 3D printing function in other ways) can print new attachment positions on the assembly line. Note that in some transport structures, a transmission may be a pressure-bearing member, so such a transmission can be considered both a standard COTS part and a structural COTS part. In some cases, advantageously, in order to suppress the cost of the machine tool and enable high-speed production of tires, the tools for the tires may be printed in the component manufacturing area 2130 or the COTS manufacturing area 2800, etc.

[0084] After the COTS parts are processed (e.g., bent, cut, printed, etc.), those COTS parts can be moved, along with the 3-D printed parts, to various subsystem construction lines 2400 (e.g., suspension, power transmission, chassis, interior, etc.) including the chassis construction line 2300. For example, the chassis construction line may comprise three robotic assembly stations including a first station 2310 for construction in a dry state, a second station 2320 for adhesion, and a third station 2330 for component construction. The chassis construction line may perform functions such as inspection (e.g., scanning), adhesive injection, bolt tightening, component placement or installation, 3-D printing, imaging (e.g., via a camera), and movement of parts (e.g., via a conveyor). Each of the other subsystems 2400 may comprise one or more robotic assembly stations. During overall assembly 2500, a final product (e.g., a vehicle suspension, power transmission, chassis, aircraft fuselage, etc.) may be assembled in each of the subsystems.

[0085] The component manufacturing system may further include additional independent inputs other than the 3-D printed structural components, standard COTS components, and structural COTS components. For example, in the vehicle body manufacturing area 2700, the system may manufacture external custom vehicle body panels and other formed custom members. The vehicle body panels may include materials such as aluminum, carbon fiber, fiber-reinforced plastic, or plastic. Manufacturing the vehicle body panels and other formed custom members on-site at the facility 2000 advantageously reduces the cost of machine tools as it does not require the expensive machine tools and stamping capital equipment used for conventional steel vehicle bodies.

[0086] The use of plastic, carbon, and / or aluminum vehicle bodies enables packaging of the vehicle body rather than painting, and advantageously reduces the environmental pollution of the facility 2000 that may be caused by painting. Packaging of the vehicle body panels can be performed last in the vehicle body panel manufacturing area.

[0087] The vehicle body manufacturing area 2700 may manufacture other formed custom vehicle body parts. For example, the vehicle body manufacturing area may manufacture a low profile custom roof rail made of carbon fiber to reduce mass and formed to match or interface with the exterior of the vehicle body of the vehicle. The formed custom vehicle body parts may be manufactured via a conventional layup process or an autoclave process. Alternatively, the formed custom vehicle body parts may be created using 3-D printed tools, which can advantageously reduce capital expenditure costs. The costs associated with the tools used to create the parts may not require amortization over a large number of vehicles. For example, a low-cost 3-D printed tool may be reused if the corresponding parts (e.g., custom roof rails) created using that tool are used in the future to manufacture other vehicles at facility 2000 or are expected to be useful for other products. Alternatively, if a system (e.g., a vehicle optimization system, an ERP system, a control system) determines that the likelihood of the tool being reused is low, the tool may be recycled through disassembly in area 2100 and recycling in the recycling area 2110.

[0088] Vehicle assembly may begin after all manufacturing inputs, such as 3-D printed parts, standard COTS parts and structural COTS parts, body parts, other tools, and / or materials, have been delivered to their appropriate locations via a transport system on the assembly line. The assembly line may include a conveyor belt, a gantry configuration, or other forms, and may transport parts above or below the line and between positions where processes are performed. Alternatively, the assembly line may include a fixed work area, in which case all processes are performed substantially in the same location. For example, as described above, the transport system may include robots or manual labor to transport parts to the work area, and different processes may be performed, for example, by enabling the robot to move relative to the work area. The assembly line may end (2900) after overall assembly 2500 and body assembly 2600, 2650 are completed. The method of assembly on the assembly line is described in more detail below. Although various systems and processes (e.g., disassembly, melting, powder manufacturing, cutting by laser and water, bending by CNC, cleaning stations, ovens, etc.) have been described with respect to the component manufacturing system of FIG. 2, those skilled in the art will recognize that assembly facilities for various types of transport structures, such as aircraft, boats, motorcycles, snowmobiles, transport structures for mass transit, etc., may include additional or different areas, systems, and subsystems as the areas described above with respect to vehicle manufacturing facilities. Further, it will be understood that a vehicle manufacturing facility need not include all of the various systems and processes described above, and that the various systems and processes need not be configured as shown in FIG. 2. Alternatively or additionally, a vehicle manufacturing facility may implement variations of the various systems and processes described. For example, the facility may include only samples of processes, such as using only COTS parts without using 3-D printed parts, or vice versa. For example, as described above, COTS parts may be cut before being bent, or may be bent before being cut.For example, as described above, the parts to be 3-D printed may be printed on the assembly line or on COTS parts.

[0089] FIG. 3 shows an alternative exemplary configuration of a parts manufacturing system 3000. As described above, the assembly of many types of transportation structures may be contemplated, but for the sake of preventing the concepts of the present disclosure from being unnecessarily ambiguous, the example of FIG. 3 is directed to a vehicle parts manufacturing system 3000. In FIG. 3, the parts manufacturing system or facility 3000 may be segmented by vehicle subsystem areas (e.g., subsystem 2400 of FIG. 2). The facility 3000 may include one or more parts manufacturing segments. For example, the facility may include a 3-D printed parts manufacturing segment 3100 and a COTS parts manufacturing segment 3200. FIG. 3 further shows a plurality of subsystems 3600 within the assembly line, and various operations common to both 3-D printed parts and COTS parts may be performed.

[0090] In an exemplary embodiment intended to improve manufacturing flexibility and efficiency, the 3-D printed parts manufacturing segment 3100 and the COTS parts manufacturing segment 3200 of FIG. 3 may operate in cooperation with each other to facilitate the assembly of one or more types of vehicles. This cooperation may be realized, at least in part, using automated constructors 1520a - x and robotic devices that may communicate with the control system 1500 via the network 1515 (FIG. 1B) in addition to the control system 1500 and the database 1510 described with reference to FIG. 1B. These automated constructors and robotic devices may move autonomously between one or more stations or assembly stations and / or perform various operations (in real time or otherwise) under the instruction of the control system 1510 based on requirements, availability, and other factors.

[0091] In the 3D printed part manufacturing segment 3100, old vehicles or old vehicle parts to be recycled can be disassembled (3010) to produce recyclable materials 3110 and non-usable materials 3205. The non-usable materials can be discarded from the system. The recyclable materials can be converted into ingots, such as by moving the materials to a blast furnace. Ingots can be produced from metals from any source, including sources other than the disassembled old vehicles and old vehicle parts. Powders can be produced from the ingots (3120), such as by gas spraying in a powder production tower. The powders can be supplied to one or more 3D printers 3130. The 3D printed parts can pass through a post-print treatment 3140, including processes such as surface treatment, cleaning, and / or heat treatment. The 3D printed parts 3400 can be stored and warehoused at the location 3101 of the first part hub (3150). The location 3101 of the first part hub may further include one or more robots, such as an automated constructor, that can move vehicle parts to the desired assembly line locations. For example, the 3D printed parts can be sent from the location 3101 of the first part hub to various locations within the assembly line via one or more automated constructors. In some cases, the parts required to build a suspension subsystem can be 3D printed within the suspension part manufacturing area 3160. The 3D printed suspension parts can be moved directly to the location 3070 of the suspension subsystem within the assembly line. Alternatively, the 3D printed suspension parts can be moved to the location 3101 of the first part hub together with other 3D printed parts, and then those parts can be sent to the location 3070 of the suspension subsystem within the assembly line. Alternatively, the suspension parts can be obtained as COTS products.

[0092] In the COTS component manufacturing segment 3200, after COTS components are received (3210) from in - house manufacturing or off - site sources, the COTS components may be subjected to CNC bending 3220 and / or cutting 3230 by means such as lasers and water jets. The COTS components customized (e.g., by bending and cutting) 3500 may be stored and warehoused (3240) at the location 3300 of the second component hub. The location 3300 of the second component hub may be equipped with one or more robots, such as an automated constructor, that can move the components to the desired assembly line location. One or more robots at the location of the first component hub and one or more robots at the location of the second component hub can be functionally equivalent. For example, the customized COTS components can be sent from the location of the second component hub to various locations within the assembly line via one or more automated constructors.

[0093] In some cases, the components required to construct the power transmission device subsystem may be manufactured within the power transmission device manufacturing area 3250. Alternatively, the components required to construct the power transmission device subsystem may be acquired as COTS components. The power transmission device components may be moved directly to the location 3060 of the power transmission device subsystem within the assembly line or, alternatively, via the first component hub or the second component hub. In some cases, the components of the interior subsystem may be manufactured within the interior manufacturing area 3260. Alternatively, the interior components may be acquired as COTS components. The interior components may be moved directly to the location 3080 of the interior subsystem within the assembly line or, alternatively, via the first component hub or the second component hub. In some cases, body packaging components such as body panels and glass may be manufactured in the body packaging component manufacturing area 3270. Alternatively, the body packaging components may be acquired as COTS components. The body packaging components may be moved directly to the location 3090 of the glass body subsystem within the assembly line or, alternatively, via the location 3101 of the first component hub or the location 3300 of the second component hub.

[0094] The positions of some other assembly lines that can be the destination for parts include the dry mounting position 3040 and the bonding and curing position 3050.

[0095] Different robotic assembly stations may be used at different positions in various stages of vehicle assembly and manufacturing. The different stations may be arranged in a way that follows a logical progression. For example, a robotic assembly station performing a previous stage may be arranged adjacent to a robotic assembly station performing a subsequent stage. In some cases, a vehicle or vehicle part can follow a route or path, and various stations may be arranged along or adjacent to the route or path. For example, the robotic assembly stations may be arranged such that parts move along a substantially straight or circular path. In some cases, the position of each assembly line may include a robotic assembly station. Throughout the various positions within the assembly line, one or more robot arm exchange stations 3020 and one or more mobile robot arm trays 3030 may be available. In some cases, the robot arm exchange station may be fixed, and the mobile robot arm tray may be able to move autonomously or be assisted (e.g., pushed) by another mobile robot such as an automated constructor. The robot arm exchange station 3020 and the mobile robot arm tray 3030 will be described in more detail below.

[0096] Figure 4 shows an example of an additional assembly configuration. Optionally, the additional assembly configuration may be used for low-volume assembly. The low-volume assembly configuration 4000 enables the complete assembly of the transport structure 4100, including the assembly of the vehicle structure within about seven stations 4001-4007. Alternatively, depending on the configuration of a particular vehicle, assembly may be completed at seven or fewer stations. Assembly may be completed at more stations than the number described above. In some cases, each station may correspond to a robotic assembly station, and each robotic assembly station includes one or more automated constructors 4120 that perform a set of one or more vehicle manufacturing processes associated with each robotic assembly station. For example, the first station may include a set of vehicle manufacturing processes related to joint assembly 4001, the second station may include a set of vehicle manufacturing processes related to flat panel assembly 4002, the third station may include a set of vehicle manufacturing processes related to adhesive curing 4003, the fourth station may include a set of vehicle manufacturing processes related to the assembly of engine suspension components 4004, the fifth station may include a set of vehicle manufacturing processes related to interior assembly 4005, the sixth station may include a set of vehicle manufacturing processes related to door and window cutouts 4006, and the seventh station may include a set of vehicle manufacturing processes related to body panel attachment and packaging 4007. In other examples, each stage of manufacturing may correspond to a robotic assembly station, and each stage includes one or more sub-stations. For example, the first robotic assembly station may include a sub-station that includes joint assembly 4001, flat panel assembly 4002, and adhesive curing 4003 in the first stage. The second robotic assembly station may include a sub-station such as the assembly of engine suspension components 4004 in the second stage. The third robotic assembly station may include a sub-station that includes interior assembly 4005 and door and window cutouts 4006 in the third stage.The fourth and final assembly station may include sub-stations such as body panel attachment and packaging 4007 in the fourth stage.

[0097] Each station and / or robotic assembly station may include three levels of operation, including high-level operation 4010, medium-level operation 4020, and low-level operation 4030. In some cases, the level of operation may be determined by the degree of involvement of one or more automated constructors tasked with performing the operation. Alternatively or additionally, the level of operation may be determined by the degree of difficulty. Alternatively or additionally, the level of operation may be determined by the degree of intervention (e.g., contact, manipulation, control, etc.) with the vehicle 4100 being assembled. Alternatively or additionally, the level of operation may be determined by the proximity to the autonomous assembly platform 4105. For example, the transport of parts and tools from the mobile supply vehicle 4130 to the autonomous assembly platform 4105 via the conveyor belt 4110 may only require the automated constructor to perform a simple task such as transporting a part or tool between two positions, and since this task is performed at a relatively long distance from the autonomous assembly platform (e.g., the end of the conveyor belt), it can be a low-level operation. For example, an operation performed on a part or tool in the middle of the conveyor belt can be a medium-level operation. For example, an operation performed on the autonomous assembly platform can be a high-level operation.

[0098] If necessary, different vehicle parts or vehicle tools may be transported as required. For example, different vehicle parts and / or tools may be transported between robotic assembly stations, or within a robotic assembly station, or from another location to a specific robotic assembly station. The mobile supply vehicle 4130 and the conveyor belt 4110 may conveniently and efficiently make the parts and / or tools required at the robotic assembly station available to one or more automated constructors associated with the robotic assembly station. For example, the mobile supply vehicle may approach the automated constructor to directly provide parts to the automated constructor. Alternatively, the automated constructor may approach the mobile supply vehicle to directly receive parts from the mobile supply vehicle. The mobile supply vehicle may provide parts via an intermediate conveyor belt. Such a conveyor belt may move parts from one location to another without the support of the mobile supply vehicle. The conveyor belt may minimize or reduce the need for the movement of the automated constructor to obtain parts. The autonomous assembly platform 4105 may be any platform that can support one or more vehicle manufacturing processes. For example, the platform 4105 may be configured to support the size and weight of the vehicle or other transport structure being assembled on the platform. The platform 4105 may include any shape (e.g., substantially circular, angular, polygonal, free form, etc.) and any suitable area. In some cases, the autonomous assembly platform 4105 may simply include an area of the ground (e.g., the floor) at the ground level of the facility 4000. In other examples, the autonomous assembly platform 4105 may be lifted above the ground level. The platform 4105 may be able to move up or down. The platform 4105 may or may not be able to move laterally or rotate. The autonomous assembly platform 4105 may be substantially parallel to the ground.The self - regulating assembly platform 4105 may be configured to rotate clockwise or counter - clockwise to enable access of one or more automated constructors to different parts of the vehicle 4100 on the platform without the need for one or more automated constructors themselves to move across inconvenient paths (e.g., move up and down or pass through a conveyor belt) to access different parts of the vehicle. The automated constructor may be able to move across the ground and around the platform 4105.

[0099] The assembly line may be monitored via one or more quality control sensors 4140, etc. The one or more quality control sensors 4140 may be fixed at a certain position throughout the facility 4,000, with a certain degree of freedom of movement (e.g., rotation, pan, tilt, etc.) or without freedom of movement. Alternatively or additionally, the one or more quality control sensors 4140 may be included in one or more robots such as an automated constructor. The quality control sensor 4140 may provide quality control and feedback to one or more transport structure manufacturing processes substantially in real time, such as by comparing the assembled product with the requirements in the desired design. The quality control sensor 4140 is communicatively coupled to the control system 1500 (FIG. 1B) and may transmit sensing data to the control system, and the control system may provide instructions to one or more robots, such as the automated constructor of the system, to continue, stop, or change one or more operations being performed by the one or more robots in response to the sensing data. The sensor 4140 may include a camera, an infrared sensor, other visual detectors (e.g., scanners, etc.), an audio sensor (e.g., a microphone), a thermal sensor, a temperature sensor, a motion detector, and / or other sensors. The sensor can detect visual and non-visual characteristics of parts, robots, tools, or any individual within the assembly station. The sensor may be assisted by one or more processors to capture one or more images, capture video, track the position, state, and orientation of parts, and / or find errors. Data obtained from the sensor may be stored in memory and / or analyzed with the assistance of one or more processors. Additionally, data collected by the sensor and the one or more processors may be communicated to a remote user.

[0100] FIG. 5 shows a schematic diagram of an additive manufacturing assembly system. The additive manufacturing assembly system may comprise a connector (e.g., a node) and a node structure including interconnecting materials that can be connected to each other via the connector. The interconnecting materials may include various standardized structural materials such as honeycomb panels, tubes, and protrusions. The connector may be 3-D printed in a component manufacturing area 2130 such as that of FIG. 2. Alternatively, the connector may be obtained as a COTS component and may be modified or used as is depending on the implementation. The interconnecting structural materials may be 3-D printed in a component manufacturing area 2130 such as that of FIG. 2. Alternatively, the interconnecting structural materials may be obtained as COTS components. In some cases, the connector and / or the interconnecting materials may partially include COTS components and partially include 3-D printed materials, such as when a portion of the connector and / or the interconnecting materials is 3-D printed onto a COTS component. Alternatively, non-printed structural materials may be manufactured within the facility.

[0101] To assemble interconnect materials together with another interconnect material via a connector, various connection techniques can be used, including the use of fasteners (e.g., screws) and adhesives (e.g., glue). For example, a first tube and a second tube may be respectively tightened to a joint using a fastener, and as a result, they are joined by the joint. In another example, a first tube and a second tube may be respectively tightened to a joint by injecting an adhesive between the joint of the first tube and the joint and between the joint of the second tube and the joint, and as a result, they are joined by the joint. The connection method may temporarily or permanently connect the interconnect materials to the joint. By utilizing 3D printing, significant flexibility can be added to the available connection methods. For example, a fastener, a mounting function for attaching the fastener (e.g., a hole of a specific diameter), and / or a flow path for introducing an adhesive can be custom-designed and 3D printed. In some cases, a fastener, a function for attaching the fastener, and / or a flow path for introducing an adhesive can be 3D printed onto a connector or an interconnect material. Flexible mounting functions can include screw, friction, key-based connections, etc., that enable a robotic assembly station to quickly and adaptively attach components.

[0102] In an example embodiment, the additive manufacturing system 5100 may implement a robotic assembly system. The robotic assembly system can increase the manufacturing speed of complex transportation structures. As described above (with respect to FIGS. 1A and 1B, etc.), a transportation structure manufacturing facility may include a plurality of robotic assembly stations, as well as a plurality of robots such as an automatic constructor and a mobile supply vehicle associated with each assembly station. The plurality of robots may be configured to jointly assemble a transportation structure passing through the assembly station within the arrangement of the robotic assembly stations and verify the quality control of the transportation structure. The robotic assembly stations may be configured with various specific functions and / or sensors that enable rapid assembly of parts of a vehicle or other transportation structure, including 3-D printed parts, COTS parts, and / or parts manufactured at the facility without printing.

[0103] The robotic assembly system may be flexible in many respects. For example, the robotic assembly stations may be configured to accommodate and assemble new and / or different structures without significant adjustment of the attachment or reprogramming of the robotic assembly system or its components (e.g., robots). For example, the designated location and / or designated area of the robotic assembly stations may be changed in real time. In some example embodiments, including the assembly of vehicles such as automobiles, multiple robots may each perform different vehicle manufacturing processes such that existing robots can be instructed to perform different vehicle manufacturing processes, and there is no need to replace the robots with different robots to perform different vehicle manufacturing processes.

[0104] The robot assembly station need not be specific to a design. As described above, different vehicle models may share one or more robot assembly stations, either simultaneously or at different times. The robot assembly station may be used to assemble structures for, for example, various different brands of vehicles, various different models of vehicles, various different categories of vehicles (e.g., trucks, trailers, buses, four-wheel drive vehicles, etc.), and / or various different categories of transport structures (e.g., boats, airplanes, motorcycles, etc.). For example, various different brands, models, and / or categories of vehicles may be presented to the robot assembly station in any order, and the robot assembly station may continue to execute a set of one or more vehicle manufacturing processes associated with the robot assembly station. Similarly, the robot need not be specific to a design. The same robot may perform the same vehicle manufacturing process (e.g., welding) for various different brands, models, and / or categories of vehicles. In some cases, different robots may share the same tool for various different brands, models, and / or categories of vehicles.

[0105] The robot assembly system may include an additive manufacturing process. The additive manufacturing process may be vertically integrated, such as by incorporating a printing machine (e.g., a 3-D printing robot) and an assembly machine (e.g., various automated constructors) into the robot assembly station. For example, small or large amounts of non-printed structural materials may be manufactured within the plant. For example, carbon fibers may be woven into a specific shape by one or more automated constructors (e.g., carbon fiber weaving robots). The carbon fiber material may be shaped into a desired 3-D design, such as by varying the individual thread lengths of the carbon fibers. In some cases, non-printed structural materials may be manufactured when required. This can advantageously reduce the inventory of individual parts. The inventory may include a stock of large amounts of raw materials for the manufacture of non-printed structural materials in response to demand.

[0106] In a robot assembly station, multiple robots may be utilized to assemble the components of vehicle 5010. For example, some robots such as a mobility support vehicle may be configured to collect 3-D printed components from a printer for transportation, collect standard COTS materials and structured COT materials such as carbon fiber tubes, protrusions, and structured panels, and collect the robot's arm from a robot arm exchange center 5100. The mobility support vehicle can include a mobility support vehicle 5210 for carrying one or more vehicle components and a mobility support vehicle 5200 for carrying one or more robot arms. For example, the mobility support vehicle 5210 may carry a tray of fasteners 5140, a tray of joints 5130, and / or a tray of COTS protrusions 5120. The same mobility support vehicle may carry components of two or more types of vehicles. Alternatively, different mobility support vehicles may carry components of different types of vehicles. In some cases, the mobility support vehicle may be specific to one or more types of vehicle components or tools.

[0107] The mobile support vehicle may move autonomously, in whole or in part, via pre-programmed instructions and / or instructions from a control system (such as control system 1500 in FIG. 1B or control system 6000 in FIG. 6 further described below). In some cases, the mobile support vehicle may include one or more sensors (such as a camera, a geographical location information device such as GPS, etc.) that communicate with the control system so that the control system can track the position of the mobile supply vehicle. In an example embodiment, the control system may form and transmit instructions using the tracked position. The mobile supply vehicle may perform rolling, rotating, walking, gliding, floating, flying, and / or combinations thereof to move between positions. The mobile support vehicle may move freely along a surface and / or along a track, within a parameter or set of parameters (such as in the lateral direction, vertical direction, etc.). In some cases, the mobile support vehicle may be configured to move such that the base moves relative to the underlying surface (such as the ground, a rope, the side of a wall, the side of a pillar, etc.). For example, the mobile support vehicle may include moving components and non-moving components. Moving components such as wheels, belts, limbs, wings, or other parts (such as teeth, etc.) may move relative to the non-moving components and move the non-moving components relative to the underlying surface.

[0108] In an example embodiment, some robots, such as an automated constructor, can be configured to attach parts, assemble parts, and apply fasteners and adhesives to vehicle parts. The automated constructor may be restricted in its freedom of movement (e.g., rotation, rotation of limbs if present, etc.) and fixed in a certain position. Alternatively or additionally, as described above, the automated constructor may move autonomously or semi-autonomously via pre-programmed instructions and / or instructions from a control system (such as control system 1500 in FIG. 1B or control system 6000 in FIG. 6). The automated constructor may freely traverse over the underlying surface. The automated constructor may freely move in any lateral direction without obstacles or obstructions. The automated constructor may include one or more processors built into the constructor that can generate commands for controlling the movement of the constructor. Those commands may be generated in response to and / or based on data collected by one or more sensors built into the automated constructor.

[0109] In an example embodiment, the automatic constructor may include one or more sensors (e.g., a camera, a geographical location information device such as a GPS) that communicate with a control system so that the control system can track the position of the automatic constructor. In some cases, the control system may use the tracked position to form and send commands. The automatic constructor may perform rolling, rotating, walking, gliding, floating, flying, and / or combinations thereof to move between positions. For example, the automatic constructor may include one or more wheels that can roll to advance the automatic constructor. The automatic constructor may move freely along a surface and / or along a track within parameters (e.g., horizontally, vertically, etc.). In some cases, the automatic constructor may be configured to move such that a base moves relative to a surface below (e.g., the ground). For example, the automatic constructor may include at least a moving component and a non-moving component. The moving components, such as wheels, belts, limbs, wings, or other parts (e.g., teeth, etc.), may move relative to the non-moving component and move the non-moving component relative to the surface below.

[0110] The automated constructor can include robots such as an adhesion robot 5330 for adhesion, a mounting robot 5320 for handling jigs, a 3D printing robot 5310 for printing 3D parts or assisting another 3D printer, a bolting robot 5340 for bolting, an arm replacement robot 5220 for replacing the arms of other robots, a protrusion robot 5300 for handling protrusions such as creating and / or attaching protrusions, a press-fitting robot (not shown in FIG. 5), and a welding robot (not shown in FIG. 5) for welding. The 3D printing robot may include a robot equipped with a 3D printer. The 3D printing robot may move autonomously or semi-autonomously, similar to other automated constructors. The mobile 3D printing robot may move to an assembly line or other work area (e.g., a platform) as required and print directly onto vehicles, vehicle parts, and / or vehicle assemblies.

[0111] Various other robots can perform mechanical processes such as cutting (e.g., cutting by water jet, laser cutter), bending (e.g., bending by a CNC machine), and milling (e.g., milling a panel to receive an insert and enable fitting to a specific shape). Alternatively, a mobile support vehicle robot may transport parts requiring mechanical processes to other machines.

[0112] The automated constructor may be configured to perform vehicle manufacturing processes with or without the assistance of one or more tools. For example, a 3-D printing robot may be configured to perform 3-D printing processes with the assistance of a 3-D printer. One or more tools (e.g., a 3-D printer) may be a permanent or removable part of the automated constructor. In some cases, the automated constructor may include one or more robotic arms 5110. One or more robotic arms may be permanently attached to the automated constructor or may be removable from the automated constructor. In one example, the arm may include a tool that can be attached to the arm, and the arm may be exchanged to replace the tool as needed. In another example, the arm may remain attached to the automated constructor, but a tool such as an end effector may be exchanged from the arm. The robotic arm may include a replaceable end effector capable of performing various operations (e.g., chassis assembly, battery assembly, vehicle body panel assembly, painting, assisting human manual work, applying fasteners, applying adhesives, applying paint, attaching components for curing, etc.). In some cases, the end effector may be replaceable. Alternatively or additionally, the robotic arm including the end effector may be replaceable. In some cases, one or more tools may be made available at various fixed positions. For example, one or more arms including replaceable end effectors may be made available at various fixed arm exchange areas 5100, and the robot may visit the arm exchange area 5100 to exchange the arm. Alternatively, tools such as one or more arms including replaceable end effectors may be made available on a mobile support vehicle 5200 configured to transport the one or more arms to various positions accessible by other robots. In some cases, the mobile support vehicle carrying one or more arms may deliver the arms to a specific robot. The available robotic arms may not be specific to the design.For example, different robots may perform vehicle manufacturing processes on different models and / or categories of vehicles using the same arm at different times. In some cases, the robotic arm may be compatible with any automated constructor such that any automated constructor can use the robotic arm. In other examples, the robotic arm may be compatible only with a particular type of automated constructor such that only that particular type of automated constructor can use the robotic arm.

[0113] In one example, a robotic assembly station can simultaneously adjust the insertion of multiple tubes into a joint from multiple angles, introduce bolted secondary features, and then inject adhesive through a 3-D printed flow path by using one or more automated constructors that include one or more robotic arms. A mounting robot can then apply an external jig to provide the proper position during curing.

[0114] FIG. 6 shows a schematic diagram of an assembly system control system 6000. In some cases, the operation of the assembly system control system 6000 and the assembly system control system may correspond to the operation of the control system 1500 of FIG. 1B and the control system 1500 of FIG. 1B. The control system 6000 may comprise one or more processors, one or more memory devices storing software instructions executed by the processors, and known computing components such as data. The one or more processors can be a single microprocessor or multiple microprocessors capable of executing a particular set of instructions, a field programmable gate array (FPGA), or a digital signal processor (DSP), or any combination of these components. The computer-readable instructions can be stored on a tangible non-transitory computer-readable medium such as a floppy disk, hard disk, CD-ROM (compact disk read-only memory), MO (magneto-optical), DVD-ROM (digital versatile disk read-only memory), DVD RAM (digital versatile disk random access memory), or semiconductor memory. In some example embodiments, the control system may use, for example, cloud storage, any future storage technology, which may be extremely important for the Internet of Things (IoT). Alternatively, the methods disclosed herein may be implemented in hardware components or a combination of hardware and software such as, for example, an ASIC (application specific integrated circuit), a dedicated computer, or a general purpose computer.

[0115] Network 6010 may be configured to connect and / or provide communication between various components (e.g., one or more automated constructors 6200, one or more mobile supply vehicles 6300, etc.) and control system 6000. For example, the network may be implemented as the Internet, an intranet, an extranet, a wireless network, a wired network, a local area network (LAN), a wide area network (WAN), Bluetooth, near field communication (NFC), any other type of network that provides communication between one or more components of the network layout of FIG. 6, or any combination of these networks. In some embodiments, the network may be implemented using a cellular network and / or a pager network, a satellite, a licensed wireless, or a combination of licensed and unlicensed wireless. The network may be wireless, wired (e.g., Ethernet), or a combination thereof.

[0116] The control system 6000 may be implemented as one or more computers that store instructions, which, when executed by one or more processors, can generate instructions and transmit them to one or more automated constructors 6200, one or more mobile supply vehicles 6300, other robots, and / or machines within the assembly system. The control system can further receive data requests and / or instruction requests from one or more automated constructors, mobile supply vehicles, other robots, and / or machines within the assembly system. Although FIG. 6 shows a single control system 6000, in some embodiments, a vehicle manufacturing facility may include one or more control systems, each of which operates substantially in parallel with the control system 6000 and / or in conjunction with the control system 6000 via a network 6010 or the like. Alternatively or additionally, the control system 6000 may be distributed across different locations within the facility. For example, a vehicle manufacturing facility may include a main control system and an ERP system, and the ERP system may be incorporated as part of the main control system. In some cases, a single computer may implement one or more control systems. Alternatively, one or more control systems may be implemented on separate computers. In certain configurations, one or more control systems may be software stored in memory accessible by other control systems (e.g., memory local to other control systems or remote memory accessible via a communication link such as a network). In some configurations, for example, one control system may be computer hardware, and another control system (e.g., an ERP system that instructs a 3-D printer) may be software executable by another control system.

[0117] One or more control systems 6000 may be used to control various components of a vehicle manufacturing facility in a variety of ways, such as by storing and / or executing software that executes one or more algorithms for achieving control. Although multiple control systems for executing one or more algorithms have been described, it should be noted that some or all of the algorithms may be executed using a single control system consistent with the disclosed embodiments.

[0118] In some cases, one or more control systems may be connected or interconnected to one or more databases, such as database 1510 of FIG. 1B. The one or more databases may be one or more memory devices configured to store data (e.g., sensor data, component manufacturing data, inventory data, etc.). In some example embodiments, the one or more databases may be implemented as a computer system including a storage device. In one aspect, the one or more databases may be used by control system 6000 to perform one or more operations consistent with the disclosed embodiments. In certain example embodiments, the one or more databases may be located in the same location as the control system and / or in the same location as other components (e.g., automated constructor 6200) on a network that may or may not be network 6010. For example, automated constructor 6200 may send sensor data to one or more databases without passing through the control system. It will be understood that one or more other configurations and / or arrangements of the one or more databases are also possible.

[0119] The control system 6000 may communicate with a plurality of users via a network 6010 or the like. For example, one or more users such as a first user 6020a and a second user 6020b may communicate with the control system. A user (e.g., an administrator of a vehicle manufacturing facility, a plant manager, etc.) may participate in the system for purposes such as monitoring the vehicle manufacturing process (e.g., the activities of robots, manufacturing efficiency, quality control, etc.) and / or providing commands to various components of the vehicle manufacturing facility (e.g., robots, machines, etc.). The communication may be one-way, for example, from the user to the control system (e.g., commands, instructions, etc.) or from the control system to the user (e.g., warnings, notifications, commands, instructions, etc.). Alternatively, the communication may be two-way between the user and the control system. In some cases, a user may communicate with other users of the system. The user may be associated with a facility and may include individuals or entities such as an administrator of the facility, an employee of the facility, a designer of a vehicle model or other transportation structure being manufactured by the facility, and a customer or potential customer of the facility. The commands provided to the command system by the user may be real-time (e.g., following the manufacture of a vehicle) commands or periodic commands at regular or irregular intervals (e.g., start of assembly or design, periodic inspections at critical stages, etc.). In some cases, the commands may be high-level, for example, to command the start or stop of an assembly or to start an existing protocol in some other way, and then the control system may execute the user commands autonomously or semi-autonomously. In some cases, the commands may be more detailed, such as controlling the individual path of a robot, controlling the movement path of vehicle parts, and controlling the schedule.

[0120] The user may be assisted by user devices 6030a, 6030b that can be equipped with an interface to communicate with the system. For example, the first user may be assisted by a first user device equipped with an interface to communicate with the system, the second user may be assisted by a second user device equipped with an interface to communicate with the system, and the nth user may be assisted by an nth user device equipped with an interface to communicate with the system, and so on.

[0121] User devices 6030a, 6030b may be mobile devices (e.g., smartphones, tablets, pocket bells, personal digital assistants (PDAs)), computers (e.g., laptop computers, desktop computers, servers), or wearable devices (e.g., smartwatches). The user device may also include any other media content player, such as a set-top box, television, video game system, or any electronic device capable of providing or rendering data. The user device may optionally be portable. The user device may be handheld. The user device may be a network device that can be connected to a network, such as a local area network (LAN), a wide area network (WAN) such as the Internet, a telecommunications network, a data network, or any other type of network.

[0122] The user device may comprise a memory storage unit that can include non-transitory computer-readable media containing code, logic, or instructions for performing one or more steps. The user device may comprise one or more processors that can execute one or more steps, for example, in accordance with the non-transitory computer-readable media. The user device may be, for example, one or more computing devices configured to perform one or more operations consistent with the disclosed embodiments. The user device may comprise a display for presenting a graphical user interface. The user device may be able to receive input via an interactive user device. Examples of such interactive user devices include a keyboard, buttons, a mouse, a touch screen, a touch pad, a joystick, a trackball, a camera, a microphone, a motion sensor, a thermal sensor, an inertial sensor, or any other kind of interactive user device. The user device may be able to execute software or applications provided by one or more authentication systems. For example, a user (e.g., a facility administrator, a plant manager, etc.) may input commands into a control system via the user device for transfer to one or more robots or machines. In another example, the user may reprogram the control system for, e.g., re-optimization of a vehicle manufacturing process or software updates. In another example, the user may choose to send an emergency stop command that can stop the operation of all robots and / or machines operating within a vehicle manufacturing facility, for safety considerations, etc.

[0123] The control system 6000 may be configured to generate instructions for one or more automated constructors 6200 and / or one or more mobile supply vehicles 6300 to move between each assembly station. For example, the control system may instruct one or more automated constructors to move autonomously between each assembly station. Alternatively or additionally, the control system may provide more detailed (e.g., step-by-step) instructions for movement between each assembly station to one or more automated constructors. In some cases, the control system may change the designated position and / or designated area of the robotic assembly stations 6100, 6120, such as by instructing the movement of one or more automated constructors associated with the robotic assembly stations. Alternatively or additionally, the robot may include pre-programmed instructions that the control system may or may not disable. In this manner, the robotic assembly stations may be flexible and modular, and the manufacturing facility may be easily reconfigured by changing the position and / or area of each robotic assembly station within the limits of the facility's location and / or area of the facility. In some cases, the control system may cooperate with other components within the same robotic assembly station to provide instructions to a component (e.g., mobile supply vehicle 6300). For example, the control system 6000 may provide instructions to all robots associated with the first robotic assembly station 6100 to stop all operations and move to the second robotic assembly station 6120.

[0124] In an example embodiment, the control system 6000 may generate instructions in real time. Real time can include a response time of less than one second, less than one tenth of a second, less than one hundredth of a second, or less than one millisecond. Depending on the implementation, each of one or more robots 6200, 6300, as described above or further described below, may be able to respond in real time to instructions from the control system. For example, through the movement of one or more automated constructors, a robot assembly station may be reconfigured in real time in terms of position and / or area and may be changed in size.

[0125] The control system 6000 may be further configured such that one or more automated constructors 6200 generate instructions for performing one or more manufacturing processes of a vehicle or other transportation structure, or one or more sets of one or more manufacturing processes. The control system may provide detailed instructions regarding performing the manufacturing process to one or more automated constructors. For example, the control system (such as a control system via an ERP system) may provide specific dimensions of vehicle parts to a 3-D printing automated constructor for printing.

[0126] In another example, the robot may move freely between and within a robot assembly station within the limits of instructions pre-programmed within the robot and / or instructions received from a control system (such as control system 1500 of FIG. 1B and / or control system 6000 of FIG. 6) and / or instructions learned by the robot through machine learning. The robot may receive 3-D printed parts for post-processing and deliver those 3-D printed parts to a robot assembly station for incorporation into a complex structure (such as a chassis). Different robot assembly stations may be arranged adjacent to or around one or more assembly lines for reasons such as efficiency, thereby allowing materials to pass through different robot assembly stations when the process is carried out.

[0127] Figure 7 shows an example of a robotic automation system. The robotic automation system 7000 may include one or more automated constructors 7200, conveyer belts 7500 for transporting one or more parts 7300, 7400 of a transport structure, sensors 7600, and one or more tools 7100. Alternatively, the system may include other transport systems such as other mobile platforms, mobile robots, and / or manual labor instead of the conveyer belts. The robotic automation system may assist with various processes performed within a manufacturing facility such as manufacturing, testing, inventory, pre-use, recycling, or disposal. The processes performed by the robotic automation system may be constructive, protective, or deconstructive as appropriate for the stage of the life cycle of the part of the transport structure being processed.

[0128] One or more automated constructors 7200 and / or one or more tools 7100 may be mobile so as to be able to move to very large parts, permanently attached parts, or stored parts. Alternatively or additionally, a conveyor belt 7500 may carry one or more automated constructors and / or one or more tools towards one or more parts 7300, 7400. Alternatively or additionally, one or more parts may be carried towards one or more automated constructors and / or one or more tools. Whether the automated constructors and tools are moved and / or whether the vehicle parts are moved may be a matter of economic and mechanical efficiency. For example, it may be more economical and mechanically efficient to move the smaller and / or lighter of two towards the larger and / or heavier of the two. In some cases, if one or more of the vehicle parts being processed are part of a large part that is inconvenient to move (e.g., via assembly, attachment), those one or more vehicle parts may first be removed from their attached state and disassembled by one or more disassembly automated constructors. After one or more automated constructors and one or more vehicle parts are carried within the reach of other automated constructors, the one or more automated constructors may perform the instructed process. In one example, the automated constructor optionally comprises an additive manufacturing machine or a 3-D printing machine to construct replacement parts for worn or damaged vehicle parts. One or more automated constructors may exchange the end effector of a robot via a usable tool. Alternatively, one or more automated constructors may exchange a robotic arm having a different end effector.

[0129] The sensor 7600 may be communicatively coupled to a control system, and further the control system may be communicatively coupled to one or more automated constructors. Alternatively, the sensor may communicate directly with one or more automated constructors and / or one or more tools. In some cases, the sensor may be an imaging device such as a camera. In some cases, the sensor may be a thermal sensor, a motion sensor, an audio sensor (e.g., a microphone), etc. The sensor may monitor the transportation structure manufacturing process (e.g., quality control checks, etc.). For example, the sensor 7600 may determine the stage of the life cycle in which one or more vehicle parts are included and transmit such data to the control system, and then the control system may instruct one or more automated constructors to perform processes suitable for a particular life cycle. The sensor 7600 may detect wear, cracks or damage of one or more parts and, via the control system, instruct one or more automated constructors to perform additive manufacturing or 3-D printing to construct replacement parts for the worn or damaged parts, etc. In one example, the sensor may be used for tightening or sealing inspections along a pipeline to remove a worn part, manufacture a new part, and attach it to the location where the worn part was removed.

[0130] Figure 8 shows an example of a structured sub-assembly. In an example embodiment, a robotic assembly station may be used to assemble a structure consisting of off-the-shelf components such as sections 8100a, 8100b, arcs, and tubes 8200. In some cases, such an assembly may require adjusted insertion (e.g., simultaneous insertion, insertion at a specific time, etc.) of multiple components into other components (e.g., sections, arcs, tubes, etc.). Such adjusted insertion may interfere with the geometric coupling of the structure. In some cases, the sub-assembled structure 8300 may be incorporated into a larger assembly 8200.

[0131] In an example embodiment, each component, assembled part, and / or sub-assembled structure may comprise one or more labels. The labels may include identification matrices such as matrices 8110a, 8110b, and 8310b. The labels may be used to detect and identify components throughout the manufacturing process and / or throughout the life cycle of the component, to determine the location, position, and / or orientation of the component, to detect errors, and / or to track and monitor the component. For example, the labels may be used to verify the correct orientation and position of a component, assembled part, and / or sub-assembled structure relative to another component, assembled part, and / or sub-assembled structure. The labels may be detected by one or more sensors (e.g., cameras) that may be positioned on an assembly line and / or on an automated constructor. After verification via the labels, the component, assembled part, and / or sub-assembled structure may be assembled via a single-motion press-into-place action, such as where an adjusted force is applied from multiple directions. This adjusted force may be programmed or (e.g., in real time) directed to be applied simultaneously or at a specific time. The single-motion press-into-place action or other insertion action may be performed by one or more robots, such as one or more automated constructors within a robotic assembly station.

[0132] FIG. 9 shows an example of a disassembly area. The disassembly area can achieve flexible disassembly by performing the steps of the assembly line in reverse order for large parts. Old transport structures or parts of transport structures may be disassembled via one or more automated constructors configured to disassemble. The disassembled components may be recycled, repaired, or discarded according to their respective states. The state of the disassembled components can be inspected by sensors such as sensor 7600 in FIG. 7, for example. Alternatively, one or more sensors may be placed on a robot such as a disassembly automated constructor to inspect the disassembled components. In some embodiments, the state of the disassembled parts may be incorporated into the disassembled parts via an identification matrix (such as matrices 8110a, 8110b, 8310b in FIG. 8) that identifies the stage of the life cycle of the disassembled parts. A control system may provide instructions for determining whether the parts are to be recycled, repaired, or discarded, or one or more robots may be pre-programmed to determine them. For example, the glass from the glass body 9100, the suspension parts selected from the suspension subsystem 9200, the interior parts selected from the interior subsystem 9300, and the carbon materials from other subsystems 9400 may be determined to be recyclable and sent to a blast furnace to be converted into ingots. Other components such as selected body parts, wheels, tires, and engines may be determined to be repairable and transported to a storage area. In some cases, the segments disassembled from one or more subsystems may be determined to be recyclable and transported to a blast furnace. In some cases, the segments may be connected to the suspension parts before being transported to the blast furnace.

[0133] In some cases, the additive manufacturing system of FIG. 5 may further include a plurality of sensors. The plurality of sensors can ensure the proper assembly and quality control of a complex-structured system being assembled within the robotic assembly station. One or more sensors may be mounted within the robotic assembly station. Alternatively or additionally, one or more sensors may be disposed on one or more robots, such as an automated constructor associated with the robotic assembly station. Alternatively or additionally, one or more sensors may be integrated into the structural product being manufactured by the system. The one or more integrated sensors may provide important feedback during the assembly process and continuous information regarding the product over its life cycle. One or more sensors may be arranged to assist with the proper positioning and stacking of tolerances. One or more sensors may further detect proper or improper performance of the product specifications.

[0134] In some cases, 3-D printed parts and / or structures can be configured to receive and / or incorporate one or more sensors. The one or more incorporated sensors may move with the 3-D printed parts and structures and / or the final product. By tracking the printed parts and structures and / or the final product via the one or more incorporated sensors, the control system may monitor product quality. In one example, a stress sensor may track and monitor the torsional performance of a vehicle that integrates the stress sensor under specific driving conditions. For example, during manufacturing, the expected stress is measured and can then be correlated with the empirical stress values measured when the vehicle later performs a similar operation. Such monitoring can provide early warning of the potential for failure and product liability damage, and then provide feedback to the manufacturing facility to increase the strength of components within the area of risk. In another example, the system may obtain frequency response measurements and / or acoustic measurements from an integrated sensor and perform a similar analysis.

[0135] Figure 10 shows an example of a robotic automation system with integrated sensors. System 10000 may include a first conveyor belt 10100 that transports a first part 10300, where the first part is monitored by a first sensor 10800, a second conveyor belt 10200 that transports a second part 10400, where the second part is monitored by a second sensor 10900, a sub-assembled structure 10600, a third part 10500, and one or more automated constructors 10700. For example, the first and second sensors may include overhead 3-D sensors (e.g., Kinect or LIDAR) that can track the positions of the arms of one or more automated constructors and the arms of one or more individuals (e.g., human operators) present within the assembly station. These sensors may be configured to predict possible movement paths and prevent collisions between humans and robots. Alternatively or additionally, if it is determined that one or more individuals are in the vicinity of one or more automated constructors, the operator of the assembly station may manually limit the range of movement and / or the range of speed of the robot, such as by providing commands via a control system. This system can advantageously protect humans safely and maximize production throughput when humans are safely away from the station. In some cases, the sensors may track an individual wearing a headset with augmented or virtual reality overlaid. In some cases, a virtual or augmented reality overlay of the assembly order and the placement of components can be provided to the individual via the headset, and these overlays may match the current configuration of the assembly order and the placement of components within the assembly station to assist and / or train the individual participating in the assembly.

[0136] In some cases, the first and second sensors may include a video camera and a data logger that can capture, document, store in one or more databases 1510 such as that of FIG. 1B, transmit, and / or share with a control system, an image or sequence of images of the assembly order. Alternatively, the image or sequence of images may be captured, documented, stored, transmitted, and / or directly shared with another control system such as the control system of another manufacturing facility. In some cases, a database documenting the entire manufacturing process may be created. The database of the entire manufacturing process can enable the performance of a complete financial, efficiency, and / or environmental analysis of the end-to-end manufacturing process.

[0137] In some cases, the robotic automation system may assist in the electromechanical interaction between an individual (e.g., a factory worker, etc.) and a vehicle, product, and / or structure being assembled. For example, the system may include automatic and / or semi-automatic mechanisms and devices such as robots for handling materials and lifting and gripping devices such as exoskeletons.

[0138] In other example embodiments, one or more robots such as an automatic constructor may include a machine-based learning algorithm (or a series of algorithms) for learning the operation dynamically on-the-fly. In these embodiments, such a robot may learn details about an operation such as spot welding or operations based on observations via the robot's sensors and / or direct experience. For example, if an error occurs during the process of a particular operation being performed by an automatic constructor, the machine-based learning ability of the automatic constructor may enable the identification of the cause of the error and possible solutions or potential solutions. In another example embodiment, the machine-based learning algorithm is incorporated into the robot itself and is adjusted in real time (or near real time), periodically, or otherwise, by commands such as settings, activation, etc. from a control system that controls the machine learning algorithm.

[0139] In an example embodiment, an automatic constructor uses machine-based learning to avoid collisions. In a manufacturing facility where a number of robots may be moving between various destinations and humans are scattered among the robots, it may be important to provide additional preventive measures in place to prevent or at least minimize damage to equipment due to accidents, or to prevent injuries. One such preventive measure may include the use of machine-based learning that enables a robot, such as an automatic constructor, to monitor the movement of other machines, learn the types and patterns of such movement, and monitor other parameters related to the movement, such as the speed, acceleration, rotational ability, etc. of other machines. Monitoring of movement patterns by a self-learning algorithm can enable a machine to continuously improve its ability to move safely within a facility by this recognition of the patterns of other machines and the recording of data and other parameters related to speed and movement.

[0140] Thus, in some cases, one or more robots may be able to learn based on a machine. Machine-based learning may enable the robot to operate autonomously, either partially or fully. For example, the robot may be able to determine and execute future actions from past actions. Machine-based learning may enable the robot to assemble specific parts (e.g., tubes, joints, etc.) at desired positions using the correct support materials (e.g., structural panels, adhesives, other sections, other components or structures, etc.) and supply the completed product automatically (e.g., independently, without pre-programmed instructions) or semi-automatically (e.g., using minimal instructions such as assigning the robot to an assembly station). In another example, machine-based learning may enable the robot to move autonomously to or determine the destination of interest. Machine-based learning may vary for each robot, such as an automated constructor or a mobile supply device. Alternatively or additionally, machine-based learning may occur at the level of the assembly station such that the learning is distributed to all robots associated with the assembly station. Alternatively or additionally, machine-based learning may be at the level of the control system such that the learning is distributed to all components connected to the control system. For example, machine-based learning at the level of the control system can improve the ability of the control system to adjust different components of a vehicle manufacturing facility without or with minimal user instructions.

[0141] Figures 19A - B illustrate a flow diagram of a method for the automatic assembly of a transport structure, according to an exemplary embodiment. Referring first to FIG. 19A, at step 1910, a first portion of the transport structure is assembled by a first automated constructor of a first robotic assembly station. For the purposes of this description, a “first” portion of the transport structure, a “first” automated constructor, and a “first” station are described, but it will be understood that two or more portions of the transport structure, two or more automated constructors, and / or two or more stations may alternatively or additionally be used. At step 1920, a second portion of the transport structure is assembled by a second automated constructor of a second robotic assembly station.

[0142] Simultaneously with or after the above steps, for example, to maximize the efficiency of build time, to reconfigure the assembly system, or for other reasons described in the present disclosure, a plurality of flexible and configurable operations may be performed. For example, at step 1930, during assembly, the first or second automated constructor may move between the first and second stations in an automated manner. As another example, at step 1940, the transport structure itself or components thereof may move between robotic assembly stations in an automated manner, for example via a conveyor belt, while being assembled.

[0143] Referring to FIG. 19B, at step 1950, the first or second automatic constructor may be reprogrammed to perform different functions. Similar to the steps above, this process may occur before, during, or after assembly, and may occur between the assembly of different model transport structures or entirely different types of transport structures. At step 1960, one or more of the robotic assembly stations may be moved to another location in real time or as a result of a set of pre-programmed instructions. For example, at step 1970, components or parts related to the assembly of the transport structure or used as part of the assembly of the transport structure may be transported between robotic assembly stations in an automated manner for use in the assembly of the transport structure at the robotic assembly station.

[0144] At step 1980, as detailed above, the automated transport structure may learn new tasks and change their operations as a result of machine-based learning techniques. As disclosed herein and at step 1990, any of these steps may include a control system that provides instructions directly or indirectly to one or more of the automatic constructors, and these instructions may be sent in real time, as part of a set of pre-programmed instructions, or as a periodically provided update.

[0145] In another example embodiment, the system may accept customer participation in the construction process. Customers such as companies, small teams, and / or individuals may use web-based design and optimization solutions to highly flexibly design the required structure of the desired transport structure, and use the tools and limitations available to the facility via variable robotic assembly stations, variable automatic constructors, and 3-D printing technology to manufacture and assemble the aforementioned design.

[0146] For example, an assembly station can be programmed and configured to use an abstract and / or high-level language that is accessible to non-programmers and individuals other than technicians. By being so accessible, end customers, including enterprises, small teams, and individuals, can, without the assistance of technicians or other experts, instruct one or more robotic assembly stations to assemble any amount of the customers' own customized transport structures. For example, an end customer may be permitted to instruct and guide the movement and sequence of robots to manufacture and assemble the end customers' own customized vehicles and be able to execute them. For example, an end customer may communicate with a control system 6000 via a network 6010 as users 6020a, 6020b. Alternatively or additionally, an end customer may communicate with the control system via a cloud or a server (such as the control server 1505 in FIG. 1B). For example, an end customer can provide user input (such as commands) using a user device (such as user devices 6030a, 6030b, etc.) equipped with a user interface to direct the movement and sequence of robots to manufacture and / or assemble a vehicle or other structure.

[0147] In some cases, an end customer may provide user input via a web interface or a virtual reality interface provided by a control server. In one example, a robot automation system integrated with sensors may track and record an individual's movement, motion, and / or direction of gaze via an individual's virtual reality headset or the like and provide such data to the end customer via the end customer's virtual reality headset that can be used by the end customer as a selection of a user device. An end customer can experience virtual reality or augmented reality during the end customer's purchase and / or assembly experience. If an end customer participates in their own construction, the end customer may satisfy any approval requirements related to participation in the construction event.

[0148] In some cases, the manufacturing facility may be configured to conduct intelligent video conferencing or other message exchanges. For example, the facility may be equipped with an integrated intelligent video conferencing and / or message exchange system to enable rapid electronic communication throughout the facility or with the outside of the facility via voice or other commands. The intelligent video conferencing and / or other message exchange system may allow the end customer to communicate in real time with the facility's employees (such as operators, workers, etc.) during the construction of the customer's vehicle, and may eliminate monitoring and intervention during the construction process if the end customer desires.

[0149] In some cases, a robot automation system integrated with sensors may take photos and / or videos of a particular customer's vehicle throughout the manufacturing and assembly processes. The system may further collect test results and inspection measurement results at each important step of the manufacturing and assembly processes. A complete database and history of the manufacturing and assembly processes of a particular vehicle may be generated for all vehicles manufactured by the facility. This database may be provided to the customer. Alternatively or additionally, the information in this database may be analyzed for research and development, etc.

[0150] In a low-volume production facility or in operations where an artistic approach or a degree of improvisation is desired (such as painting, design), a remote customer or operator may access the manufacturing and assembly processes via a web interface or virtual reality interface over the Internet and provide instructions (such as guiding the movement of a robot, etc.) to assist in the assembly process of the structure by the methods described above.

[0151] In some cases, the manufacturing facility may further comprise an identification system for the additively manufactured parts. This identification system may enable accurate repetition of the assembly of complex structures. Accurate identification of parts and the information associated with the parts may have beneficial applications in various operations related to safety, manufacturing, assembly, distribution, logistics, fraud, authenticity verification, sales, maintenance, repair, storage, handling, recycling, and disposal.

[0152] As briefly described above, the identification system may include labels such as identification matrices. The labels may be adhered as labels or stickers, etched, printed, or attached by other means to vehicle parts or structures. FIG. 11 shows an example 11000 of a part 11100 with an integrated label 11200. For example, the label 11200 may be integrated at any position on the surface of the part 11100.

[0153] FIG. 12 shows an example of a label. The label 12000 may be any type of machine-readable graphic mark such as an identification matrix. The label may or may not be encoded and may include descriptive data. The descriptive data may include data such as symbol format, data character encoding method, capacity, dimensional characteristics, error correction rules, encoding and decoding algorithms, user-selectable application parameters, and specific units of information.

[0154] The label 12000 may be associated with specific information that can be stored in another database, such as one or more databases 1505 in FIG. 1B that can be accessed by a control system such as the control system 1500 in FIG. 1B. For example, a robot and / or control system may communicate with and search one or more databases regarding the label when reading the label to detect the specific information associated with the label.

[0155] In one example, labels such as identification matrices may simply identify the components and subsystems of which they are a part. A catalog of the necessary assembly information, which can include information such as which components are required for which subsystems, may be stored in one or more databases. In another example, the label may simply identify the requirements information of the final product. Based on the requirements information of the final product, a robot (e.g., an automated constructor) may perform one or more vehicle manufacturing processes through machine learning in accordance with the requirements information of the final product. In another example, the label on a component may provide detailed information about the component or the assembly of the component, such as relationship information (e.g., the position and location of a component relative to another component or another assembled product). The relationship information may disclose the particular assembled product into which the component or another assembled product (e.g., a sub-assembly) is incorporated. The detailed information including the relationship information may be stored in one or more databases that can be accessed by a control system and / or one or more robots that can read the label so that the control system and / or one or more robots can find the detailed information associated with the label.

[0156] In some cases, the label on a component may provide information about the gripping position. For example, the label on a component may disclose that, with respect to that component, there is a handle or screw hole specifically designated to be gripped, or a flat and smooth surface that may fit an adsorption cup. Each position of one or more gripping positions may be described using coordinates relative to the position of the label. Such information may be useful for a robot (e.g., an automated constructor) to determine the appropriate approach path and gripping angle of the gripping part when gripping the component.

[0157] FIG. 13 shows a flow diagram of a life cycle 13000 of a 3-D printed component with an integrated label. For example, the 3-D printed component 13400 may be a component of an automotive subsystem, a part of an aircraft or air conditioning equipment, or other useful objects for industrial, military, commercial, or consumer use. In a first step 13100, the component may be specified. In the component specification, in addition to the part identification number or name specific to the component, the requirements of the component such as size and function may be identified. The component specifications may be collected for use in subsequent steps. In a second step 13200, a label can be created, which is associated with the descriptive data regarding the component. This descriptive data may be stored in one or more databases accessible by a control system. This descriptive data may or may not be encoded in the label. If encoded, the label may be encoded using a standard (e.g., ISO / IEC 18004 standard) or non-standard algorithm. The label may be machine-readable.

[0158] In the next step 13300, the component can be designed on a computer (e.g., using computer-aided design (CAD) software) and / or selected from a library of pre-designed parts or standard parts. A 3D model or design form of the part can be defined. A label created previously for the component can be integrated into the 3D model or design of the component. The component may include multiple labels. A descriptive computer 3-D data model 13400 of the component with an integrated label can be generated. The 3-D data model can be stored as a computerized descriptor file in a transferable digital format (e.g., STEP, STP, SLDPRT, EPRT, etc.). The descriptor file may include various items of data and metadata, including part number, physical dimensions, shape, color, material specifications, weight, geometric tolerances, and / or other alphanumeric and symbolic descriptions. In the process of saving the file, some data items may be optionally omitted or deleted from the file, leaving only the geometric outline and basic description of the part. Deletion or extraction of the file's data or metadata may be performed to remove large amounts of irrelevant data from the file for manufacturing, physical processing, and / or publication, and optionally save memory space. The label may remain unconditionally and be permanently incorporated into the model of the component, and may not be easily removable without a risk of some undesirable side effects, including loss of any functionality.

[0159] In the next step 13500, an additive manufacturing machine or a partially or fully automated facility may render the 3-D model data of the component into the physical component 13410. For example, the additive manufacturing machine or facility may be equipped with 3-D printing technologies such as selective laser melting or selective laser sintering. For example, the process may use a 3-D printer (e.g., Stratasys J75) or a similar tool. The physical component may be formed from a variety of materials, including plastic, stainless steel, maraging steel, cobalt, chromium, inconel, aluminum, gold, titanium, or other materials. The component may be manufactured from one type of material (e.g., plastic). Alternatively, the component may be manufactured from a composite of two or more materials.

[0160] The rendered physical component 13410 may correspond one-to-one to the 3-D model data of the component that includes the embedded label. For example, the label may be physically formed on the component (e.g., etched, printed, etc.) at the same time the component is 3-D printed. The descriptive data encoded in the label may include, for example, a part number, a revision code, and a unique serial number. The unique correspondence of the label on the physical component to the label on the 3-D model data of the component may enable the label on the 3-D model data of the component to function as a reliable reference point throughout the life cycle of the component. For example, the identity and revision level of the component can be easily verified at each step of the component's life cycle to ensure the correctness, origin, and history of the component. The identification system can advantageously provide a high level of reliability for the hygiene of the secure supply chain and counterfeiting prevention, thereby improving the performance and reliability of the component and / or the final product manufactured from the component.

[0161] An identification system may be used to track and monitor components through various stages of the life cycle. Specifically, the identification system may be used in configuration control and manufacturing assembly processes such as assembly, sales, logistics, and revision management operations 13600. For example, a label may be associated with the order number of the ordering customer or an order code defined by the customer. Customers who value specifications and materials unique to an order can use this label to eliminate contamination of the supply chain from counterfeits or low-quality generic parts and prevent the risk of misunderstandings downstream in the supply chain. In some cases, the identification system may be used for configuration management and preflight checks 13700 for service life and reliability prediction. For example, an assembly containing multiple additively manufactured components each identified by a unique label can be inventoried in a relatively short time (e.g., less than 1 second) and simultaneously verified for validity from a certain perspective. This can advantageously reduce the time for inventory and at the same time improve the accuracy of comprehensive inventory records of hardware components. The inventory records are easily traceable, verifiable, and reliable.

[0162] In some cases, the life cycle of a component can be monitored, such as by tracking and verifying manufacturing processes 13800 for maintenance, failure, forensic, repair, reuse, and replacement. This record can drive reliability prediction and trigger preventive maintenance at specified intervals (e.g., miles traveled, hours of use, stress history). Component replacement can be made quicker and accurately specified if necessary. The reliability is enhanced by anti-tampering identification marks for both the component and the 3-D data model, and the life cycle of the component can be accurately tracked. The overall reliability provided by the identification system can advantageously increase the value of used goods (e.g., repaired products) sold through one or more secondary channels and the aftermarket because it can verify the information of the manufacturer of the product (e.g., design, material, use, life cycle) for each individual component.

[0163] In some cases, the identification system may enable the tracking and verification of components related to the end-of-life product process 13900, including the disposal, insurance, reuse, scrap, recycling, and environmental processes of end-of-life products. For example, after a component reaches its predicted life and is decommissioned, the component can be tested to estimate any additional useful life or remaining useful life that may still be left. Components may be discarded with some additional useful life remaining, such as to maintain a safety margin, and it may be wasteful to discard components with excessive remaining life. Components that are detected to have some additional useful life can be reused, for example, in applications where safety is not as critical or in applications that are relatively less affected by component failures. Such reuse can have economic value in the aftermarket (e.g., the used parts market) and with respect to insurance appraisals for long-life vehicles with long mileage histories. The ability to track remaining useful life is particularly useful and valuable in the case of capital-intensive industrial and military equipment and platforms with long useful lives. In the case of disposal and recycling, in particular, for environmental compliance, metal recovery, and other reuse applications, accurate and specific records of material and chemical properties are required, and embedded labels can provide a verifiable and reliable link to manufacturing records.

[0164] In some cases, label geometric metadata can be used to identify the location of components that include labels on their surfaces.

[0165] Data matrix labels, such as identification matrices, may include one or more registration marks or alignment marks at the boundaries of the data matrix label, etc., that can assist in the accurate reading of the data matrix label. FIG. 14A shows an example of an identification matrix that provides boundary marks. For example, the identification matrix 14000 may include a first corner mark 14100, a second corner mark 14200, a third corner mark 14300, and a data area 14400. In some cases, these three corner marks may outline the data area and align the data area so that a sensor (e.g., a camera, scanner, or other imaging device) can detect the identification matrix as an identification matrix and identify the data area. Alternatively or additionally, the corner marks may convey non-symbolic information or metadata regarding the data area. Specifically, each of the corner marks, or alternatively, a combination of two or three of the corner marks, may provide a reference for position and / or orientation that conveys the position and orientation of the part containing the identification matrix in six dimensions including the X, Y, Z, and pitch, roll, and yaw of the part relative to the workplace.

[0166] For example, the corner marks 14100, 14200, and 14300 can be used both to identify the identification matrix as a valid identification matrix and to define the geometric position and angular field of view of the identification matrix relative to the imaging device (camera) before the imaging device (camera) reads and decodes the data area 14400. Additionally, the corner marks may identify the boundaries of the data area containing the encoded data.

[0167] The identification matrix can be read by a sensor such as an imaging device. The imaging device may include one or more processors and a memory containing instructions executable by the one or more processors to perform reading, decrypting, decoding, and / or other processing (e.g., determination of shape) of the identification matrix. Alternatively, another computing device may perform reading, decrypting, decoding, and / or other processing of the identification matrix. For example, the data within the identification matrix may be decoded and verified using an embedded cyclic redundancy code. One or more processors of the imaging device and / or another computing device may extract and identify the geometric position and orientation of the corner marks. FIGS. 14B and 14C show examples of geometric metadata extracted from the identification matrix. FIG. 14B shows a separated matrix, and FIG. 14C shows the same matrix on the surface of a component. For example, the geometric metadata of matrix 14000 can include the corner position 14500 of the reference XYZ coordinates and the reference orientation vector 14600.

[0168] The XY (e.g., X, Y axes) position of matrix 14000 is first identified by a sensor that reads the matrix and can be calculated in a coordinate framework (e.g., XY coordinates) referenced to the sensor. For example, the XY coordinates can be first identified as the coordinates of the camera of the sensor that reads the matrix. Next, using well-known geometric transformations, the camera coordinates can be transformed into the three-dimensional XYZ coordinates of the workplace.

[0169] The XYZ coordinates may include coordinate points on three axes (e.g., the X, Y, and Z axes). The corner positions of the reference XYZ coordinates may include three-dimensional coordinates of the positions of the matrix within the three-dimensional space. Since the identification matrix may be designed to be disposed at a fixed position relative to the components, the position of the matrix can be referred to as a high-precision reference code for identifying the positions of the components within the working space, such as in the autonomous assembly platform 4105 of FIG. 4. Thereby, the matrix can provide reference coordinates that are useful for material handling, virtual attachment, and other applications that require knowledge of the components within the working space. The reference coordinates can be used, for example, to guide one or more automated constructors and / or one or more mobile supply devices for robot gripping, clamping, drilling, milling, surface treatment, and other manufacturing and processing steps.

[0170] In another aspect, the orientation of the matrix image 14000 can be determined by converting the angle measured within the two-dimensional plane of the matrix surface, such as in FIG. 14C. The world positions of the matrix image and the camera are sufficient to determine the position and orientation of the part in six dimensions (X - Y - Z, pitch - roll - yaw). FIG. 14D shows the deformation of the identification matrix at the roll angle and pitch angle. Using the azimuth vector 14600 as a reference, the roll angle 14700 of the matrix can be defined as the rotation angle around the azimuth vector 14600. The pitch angle 14800 of the matrix can be defined as the rotation angle around the axis of the matrix perpendicular to the pitch angle, and this axis exists within the plane of the matrix. The fields of view of a single sensor of the matrix can be used to measure both angles simultaneously. For example, the roll and pitch orientations of the matrix can be extracted by measuring the projective distortion. Since it can be known that the matrix is manufactured in an exact rectangular form, it can be speculated that the deviation from a perfect straight line is introduced by the deviation of the environment. These deviations can be quantitatively measured using well-known machine vision image analysis and pattern recognition techniques. Projective distortion can be mainly introduced by the deformation in the orientation and pose angles of the components.

[0171] Figures 15A and 15B show a rectangular integral part 14010 labeled with six data matrices (three are visible in each figure), and each matrix is on a separate facet in two different orientations. Figure 15A shows the rectangular integral part in a first orientation. Figure 15B shows the rectangular integral part in a second orientation. For example, the rectangular integral part can be additively manufactured (e.g., 3-D printed) so as to embed a unique matrix into each of the rectangular faces. When the rectangular part is on a flat surface, one of the matrices faces upward (e.g., face 14011 in Figure 15A, face 14012 in Figure 15B). This enables quick visual identification of the orientation of the part when viewed from above. In Figure 15A, face 14011 faces upward and is labeled with the first matrix 14000a. Face 14012 faces forward and is labeled with the second matrix 14000b, and face 14013 faces right and is labeled with the third matrix 14000c. The other three faces are not visible in the first orientation. The arrows on each of the matrices 14000a - c indicate the reference orientation of the matrix. The orientation of the rectangular part can be determined by looking at any one of the matrices such that additional information is redundant in determining the orientation. In Figure 15B, face 14012 faces upward and is labeled with the second matrix 14000b. Face 14016 faces forward and is labeled with the fourth matrix 14000d, and face 14013 faces right and is labeled with the third matrix 14000c. The other three faces are not visible in the second orientation. The arrows on each of the matrices 14000b - d indicate the reference orientation of the matrix. The orientation of the rectangular part can be determined by looking at any one of the matrices such that additional information is redundant in determining the orientation. From a comparison of the two Figures 15A and 15B, it can be determined that Figure 15B is the same rectangular part as Figure 15A rotated in the upward direction.

[0172] As can be seen in the above example, when an observer (e.g., an imaging device) has partial knowledge about another pose of a rectangular part, from seeing any one face once, any geometric movement or rotation of the rectangular part 14010 can be inferred and accurately calculated. In this way, the matrix can function as a reference code that can identify the position and orientation of the part regardless of the pose. As long as the matrix is visible and readable, there is no need to look at any other part of the part. The above example describes a rectangular part with six faces and six natural poses or rest positions on a flat surface. Parts with fewer than six or more rest positions can be corresponded by appropriately labeling one or more of the faces with a visible matrix. It is not necessary to label all the faces. As long as the matrix is visible, the part can be made distinguishable in terms of position and orientation. For example, only two matrices may be needed to completely distinguish one sheet of paper. Parts with more faces or complex shapes may require more matrices. Alternatively, complex parts can be corresponded by using additional imaging devices (e.g., cameras) in the workplace.

[0173] From the above example, a method for identifying one or more components is provided. This method may include detecting the presence of one or more parts, counting the number of visible parts, classifying the visible parts (e.g., serial numbers), specifying the position of the parts (e.g., measuring the position and / or orientation), and defining a certain process as a target (e.g., determining an approach path and a gripping position, etc.). For example, the position and / or orientation of the parts may be used to guide a robot such as an automatic constructor to perform one or more processes.

[0174] FIG. 16 shows an example of an assembly 16000 composed of six components. Each of the six components can be additively manufactured with its own unique identification matrix. The matrices 16001, 16002, 16003, 16004, 16005, and 16006 on each component can be manufactured on the surface of each component. When the components are assembled together, all six matrices can be oriented in substantially the same common direction, and can be read or photographed by an imaging device, such as by viewing all six individual matrices from one side of the assembly using a single illumination source in one viewing. For example, an inventory of the complete configuration can be performed and completed by viewing once using a single illumination source by an imaging device. In some cases, other faces of the six components may include similar matrices (e.g., visible from other viewing angles). The assembly and / or the components of the assembly can be designed such that each of the multiple faces of the component includes an identification matrix that can be viewed from different viewing angles, so that an inventory of the complete configuration of the assembly can be performed from many or all sides of the assembly.

[0175] In some cases, the matrix can be used to identify the presence of the assembly or sub-assembly, as well as to specify its location and orientation. This approach can be advantageously used during material handling and during the assembly of systems or subsystems. The matrix labeling system can be used as a control basis to enable greater automation and robotic systems. This identification system can provide identification, geometric matrix data, tracking, pre-placement, and inventory of one or more components involved in one or more processes during one or more processes such as manufacturing, upgrading, and repair.

[0176] FIG. 17 shows an additively manufactured component 17000 that includes two spatially distributed matrices 17100 and 17200. Both matrices may be permanently attached to the component, and their positions may be stable relative to each other. If two or more matrices are visible on the component, since the XYZ positions of each matrix on the component are known (e.g., from the design of the 3-D model of the component), each matrix may include geometric endpoints, and a clearly defined line may be drawn between two geometric endpoints. The position of a line in space can be identified with high precision and high accuracy. FIG. 18 shows an arrangement that includes three spatially distributed matrices 18400, 18500, and 18600. A third matrix may be added to provide full dimensionality and additional accuracy. These three matrices define three lines, a first line 18100, a second line 18200, and a third line 18300, to form a triangle in a plane of three-dimensional space. The system may identify the exact position and orientation of the component that includes the three matrices by the plane that includes the triangle.

[0177] This triangulation method can provide additional self-checking capabilities through the measurement of errors such as the correspondence of lengths and / or angles within a component. If the cumulative error between the XYZ positions of the measured (e.g., empirical) matrix and the XYZ positions of the modeled (e.g., theoretical) matrix is small, the accuracy and / or exactness of the position and orientation of the part can be considered high, and vice versa. For example, to generate an error estimate, the empirical and theoretical lengths of each line between any two matrices may be compared. In some cases, the theoretical measurement may be performed on a CAD model. In another example, an orientation vector can be measured for each matrix using a previously disclosed method or the like. To calculate local deformations and errors, the agreement or disagreement between pairs of vectors of the matrix between any two matrices may be used. For example, in FIG. 18, three matrices are shown to be all in a single plane, suggesting that theoretically, the three orientation vectors of the three matrices should all be parallel. However, the measurement of the matrix from an actual physical model may generate non-parallel orientation vectors. The difference between the theoretical measurement and the empirical measurement can be used to estimate the variation of the physical component from its computer model.

[0178] The deviation of empirical measurements (e.g., of physical components) from theoretical measurements (e.g., of computer models) can arise from multiple reasons, including measurement errors, incorrect calibration, lens aberrations, numerical calculation errors and conversion errors, environmental errors and / or systematic errors, or other influences (e.g., fraud). Components of a precisely manufactured model may be used in testing the reliability of a sensor measurement system. For example, a properly calibrated system may be expected to exhibit error characteristics that spread over a relatively narrow operating range. The behavior of random errors within a relatively narrow range may sometimes suggest that the system is operating properly. In another example, calibration drift, or incorrect calibration, may increase the error range significantly enough to be detectable. The increase in the spread of errors can advantageously provide useful early warnings and indications of system (e.g., sensor, 3-D printing) failures. For example, a sensor with a changed or shifted mounting position introduces very large errors.

[0179] In some cases, counterfeit or forged parts can be detected by the error shape characteristics of the forged parts when compared to the components of a precisely manufactured model. For example, a common error made by counterfeiters can be low-precision geometric registration regarding features separated on both sides of the forged product. For example, in FIG. 15A, the positions and orientations of the matrices 14000a - c of the forged product may include multiple error symptoms. Those symptoms may be useful in detecting and diagnosing manufacturing defects, environmental or temperature variations or damage, and counterfeit or forged parts.

[0180] In some cases, subtext coding may be used to distinguish counterfeited products. Multiple matrices on a solid object can provide an anti-counterfeiting mechanism, enabling rapid inspection and detection of unauthorized parts. This mechanism can be non-symbolic and non-digital. Additive manufacturing can enable fine adjustment in the dimensions of the matrix. One such dimension can be the XY displacement of the matrix on a flat printed plane. For example, in FIG. 15A, the position and orientation of the first matrix 14000a can be easily displaced within the printed plane without affecting the fit or function of the rectangular part. This offset can introduce a perturbation in the line length of a triangle to be measured, which is engraved in this case and can be the triangle formed by matrices 14000a to c according to FIG. 18. For example, an intentionally introduced displacement can intentionally lengthen the line length between two matrices 14000a and 14000b. This displacement can be recorded in the computer model of the part and reflected in the manufactured part. Information regarding this displacement can be hidden so that it can be determined that a counterfeiter cannot detect or measure the introduced displacement, or that it is difficult to do so. In some cases, different displacements can be introduced into other similar parts, thereby making it even more difficult for a counterfeiter to learn about the displacement by examining one or more matrices on the part, even after examining a number of similarly marked parts. However, a particular displacement can be easily revealed to and detected by system-specific sensors during, for example, a routine routing configuration scan of the part.

[0181] This approach can "hide" the identity verification data by encoding it between geometric metadata items, thereby providing immediate verification to systems with knowledge of the geometric metadata and providing resistance to unauthorized systems without knowledge of the geometric data. This anti-counterfeiting mechanism can greatly simplify and speed up the detection of counterfeit parts and can be inexpensive for authorized users. This anti-counterfeiting mechanism can build a cost barrier and a complexity barrier against counterfeiters, thereby preventing fraud related to genuine manufactured products and replacement parts.

[0182] Figure 21 shows an exemplary laser cutting process. This process may occur, for example, in relation to the laser cutting process of step 2200 of FIG. 2. Automatic constructors 2102 and 2104 each include effectors 2100a and 2100b. An exemplary COTS carbon fiber panel is provided from the COTS receiving area 2209 or the COTS manufacturing area 2800 (FIG. 2) to the laser cutting station 2200. The automatic constructors 2102, 2104 may receive instructions and specifications regarding the cutting of the panel, and as a result, if the effectors 2100a and 2100b for performing the cutting of the panel are not yet attached, they may be attached. As a result, the cut panel may be provided to the chassis construction line 2300 (FIG. 2) or another suitable location for further processing.

[0183] Figure 22 shows an exemplary automated process for the assembly of panels that include joints or protrusions. This process may occur, for example, in a vehicle body assembly area, 2600, 2650 (FIG. 2), overall assembly 2500, or another suitable location. Here, automated constructors 2202, 2204 are self-equipped with effectors to manipulate the COTS carbon fiber panel 2206 to perform the assembly and / or attachment of panels that include joints or protrusions. In this figure, the end of panel 2206 includes a protrusion 2208. Automated constructors 2202, 2204 use an autonomous machine learning program or instructions from a control station to cooperate to assemble panel 2206 and insert protrusion 2208 into the appropriate position.

[0184] Figure 23 shows an exemplary laser cutting process being performed at an assembly station, similar to FIG. 21. FIG. 23 may include panels 2310a, 2310b on an assembly line being processed by automated constructors 2302, 2304, 2306, 2308. In an exemplary embodiment, panels 2310a, 2310b are being transported on a mobile assembly line and the laser cutting process occurs as the panel segments are being transported. In other embodiments, panels 2310a, 2310b may arrive at the station by a moving vehicle, automated constructor, manually, or other means.

[0185] FIG. 24 shows an exemplary process for the application of an adhesive being performed at an assembly station. FIG. 24 is an example of a function that may be performed on the chassis construction line 2300 (FIG. 2). Automated constructors 2402, 2404, 2406, 2408, and 2412 are applying an adhesive to the carbon sheet 2410 to build nodes and assemble other components. Division of labor among the automated constructors may be included. For example, some of the automated constructors may wear end effectors to move the carbon sheet or otherwise manipulate the carbon sheet, and other automated constructors may wear end effectors to apply the adhesive. In other embodiments, the carbon sheet or other materials may be movable along the automated assembly line. In one example embodiment, the entire process may be automated.

[0186] FIG. 25 shows an exemplary process performed by a plurality of automated constructors cooperating to bond and assemble protrusions to a node. The node, node assembly, or node network 2516 is placed at a station where automated constructors 2502, 2508, 2510, and 2512 are applying protrusions to the node 2516. For example, the automated constructor 2512 is wearing an end effector for assembling the protrusion 2520 to a portion 2518 of the node 2516. Next, the automated constructors 2504, 2506 may apply the panel 2522 or other components in sequence after the protrusion has been assembled. This process may occur as part of the chassis construction 2300, overall assembly 2500, or other suitable area or station (FIG. 2).

[0187] FIG. 26 shows an exemplary process performed by a plurality of automated constructors 2602, 2604, 2606, 2608 to assemble a vehicle suspension to a chassis. This process may be performed, for example, on a chassis construction line 2300, general assembly 2500, vehicle body assembly 2600, 2650, or another suitable area (FIG. 2). Referring to FIG. 26, it can be understood that a plurality of automated constructors are working together to assemble a suspension system (partially hidden from view) to a chassis 2620.

[0188] FIG. 27 shows an exemplary process performed by a plurality of automated constructors 2706, 2708, 2710 in the process of lowering a vehicle body 2702 onto a chassis 2704. This process may occur, for example, in general assembly 2500 (FIG. 2). In this example, automated constructors 2706, 2710 are equipped with tools or effectors to manipulate the vehicle body 2702 for insertion onto the chassis 2704. Depending on the embodiment, the process may be partially or fully automated.

[0189] The foregoing description is provided to enable a person skilled in the art to practice the various aspects described herein. Various changes to these example embodiments presented throughout the present disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to other technologies for 3-D printing components of transport structures. Accordingly, the claims are not intended to be limited to the example embodiments presented throughout the present disclosure, but rather to cover the full scope consistent with the literal claims and to include all structures and functions that are structurally or functionally equivalent to the elements of the example embodiments described throughout the present disclosure that are known or later become known to those skilled in the art. Further, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. A claim element should not be construed under 35 U.S.C. § 112, paragraph (f) or the equivalent provisions of similar laws in the applicable jurisdiction, unless the element is explicitly recited using the phrase "means" or, in the case of a method claim, the phrase "step of" when the element is not otherwise recited.

Claims

**Claim 1** An automated assembly system for the transport structure, comprising a three-dimensional (3-D) printer configured to print at least a part of the components of the transport structure, wherein the automated assembly system further comprises a first automated constructor configured to receive the components, and a plurality of automated constructors including a second automated constructor disposed at a first robotic assembly station among a plurality of robotic assembly stations, the first automated constructor moving the components to the second automated constructor, and the components being attached during the assembly of the transport structure, and the first and second automated constructors are configured to move between the first robotic assembly station and the plurality of robotic assembly stations in an automated manner. **Claim 2** The automated assembly system according to claim 1, wherein at least a part of the plurality of automated constructors are configured to move between a plurality of stations in an automated manner by a control system. **Claim 3** The automated assembly system according to claim 1, wherein at least a part of the 3-D printer or the plurality of automated constructors comprises one or more sensors configured such that at least a part of the plurality of automated constructors can adaptively execute one or more machine learning functions respectively. **Claim 4** The automated assembly system according to claim 3, wherein the one or more machine learning functions include optimizing the movement pattern of the print, enabling motion control of the print head, dynamically adjusting and printing for material development and structural optimization, or automatically receiving tools for vehicle assembly. **Claim 5** The automated assembly system according to claim 1, wherein the 3-D printer comprises an automated robotic device having a robotic arm together with a robotic effector at the tip of the robotic arm, and the robotic effector is configured to move the components to the second automated constructor. **Claim 6** The automatic assembly system according to claim 1, wherein the first automatic constructor comprises an automatic robot device having the robot arm together with an end effector of the robot at the tip of the robot arm, and the end effector of the robot is configured to move the component to the first robot assembly station.

7. The automatic assembly system according to claim 1, further comprising a controller for controlling the automatic constructor during the assembly of the transport structure, including the movement of the component from the first automatic constructor to the second automatic constructor.

8. The automatic assembly system according to claim 1, further comprising a plurality of robot assembly stations, wherein the first automatic constructor is configured to reciprocate between the plurality of robot assembly stations during the assembly of the transport structure.

9. The automatic assembly system according to claim 8, wherein the three-dimensional (3-D) printer is configured to reciprocate between two or more of the plurality of robot assembly stations during the assembly of the transport structure.

10. The automatic assembly system according to claim 1, wherein the second automatic constructor comprises an automatic robot device having the robot arm together with an end effector of the robot at the tip of the robot arm, and the end effector of the robot is configured to be used during the assembly of the transport structure.

11. The automatic assembly system according to claim 10, wherein the second automatic constructor is configured to automatically exchange the robot arm with another robot arm during the assembly of the transport structure.

12. The automatic assembly system according to claim 10, wherein the second automatic constructor is configured to automatically exchange the end effector of the robot with an end effector of another robot during the assembly of the transport structure.

13. The automatic assembly system according to claim 1, wherein the three-dimensional (3-D) printer is configured to print at least a part of the component by printing a first part of the component on a second part of the component that is not formed by printing.

14. The automatic assembly system according to claim 1, wherein the three-dimensional (3-D) printer is configured to print at least a portion of the components by printing interconnections configured to interconnect the components in a different structure.

15. The control system is configured to control the three-dimensional (3-D) printer to print at least a portion of the components of the transport structure, control the first automatic constructor to move the components to the first robotic assembly station, and control the second automatic constructor to attach the components during assembly of the transport structure. The automatic assembly system according to claim 2.

16. The first automatic constructor is configured to move back and forth between the first robotic assembly station and the plurality of robotic assembly stations, and the base of the first automatic constructor moves relative to the surface below. The automatic assembly system according to claim 1.

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