Ford Global Technolgoies, LLC

Arnon Wexler

Elizabeth Therese Hetrick

Emily Ann Ryan

Oludele Olusegun Popoola

Daniel Edward Wilkosz

Jan Birger Skogsmo

Larry Van Reatherford

Larry V Reatherford

Francis Maslar

Ronald Paul Cooper

Alexander Marrocco

Robert Alan Jones

Peter L Busuttil

Neil G Greig

Tamara Hanel

Robert Koehl

Edgar De Vries

Matthew Gilloon

Hussein Chami

A method of joining at least two substrates includes welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes: reducing a mismatch between the at least two substrates by melting on both sides of the at least two substrates to form a melted portion that does not overlap a joint line between the at least two substrates with a first welding step; and increasing melt volume and penetration depth of the melted portion between the at least two substrates with a second welding step.

Laser welding of square butt joints between copper substrates

A method of joining electrical connections together includes evaluating at least one weld joint between at least two substrates, determining mismatch between the at least two substrates, and welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes compensating for mismatch between the at least two substrates by welding on both sides but not overlapping a joint line between the at least two substrates with a first welding step and increasing melt volume and penetration depth of a weld between the at least two substrates with a second welding step.

Laser edge welding of copper substrates

A method of joining electrical connections together includes evaluating at least one weld joint between at least two substrates, determining a mismatch between the at least two substrates, and welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes compensating for the mismatch between the at least two substrates by welding on both sides but not overlapping a joint line between the at least two substrate with a first welding step and increasing melt volume and penetration depth of a weld between the at least two substrates with a second welding step.

A system for assembling a vehicle platform includes a robotic assembly system having at least two robotic arms, a vision system capturing images of an assembly frame, and a control system configured to control the robotic assembly system to assemble the vehicle platform based on images from the vision system, force feedback from the at least two robotic arms, and a component location model. The control system is further configured to identify assembly features of a first component and a second component of the vehicle platform from the images, operate the robotic arms to orient the first component and the second component to respective nominal positions based on the images and the component location model, and operate the robotic arms to assemble the first component to the second component based on the force feedback.

Method and system for fixtureless assembly of a vehicle platform

A method is disclosed for welding a first part and second part together. A spacer bead is first formed on the first part by directing a laser beam on one side of the first part. The second part is then assembled to the one side of the first part. The second part is then welded to the first part by directing a second laser beam in a partially circular pattern adjacent the spacer bead. An end portion of the weld terminates radially inside the partially circular pattern.

Laser welding process

A welding system is provided. The welding system includes a fixture, a plurality of pressure blocks, and a laser welder. The fixture is configured to grasp a roof panel and transition to an advanced position in order to align the roof panel with a roof rail along a weld line. The plurality of pressure blocks are movably secured to the fixture such that advancing the pressure blocks when the fixture is in the advanced position provides a compression force between the roof panel and roof rail along the weld line to prevent distortion during a welding operation. The laser welder is configured to weld the roof panel to the roof rail along the weld line.

Welding system for vehicle body components

A method and apparatus for joining multiple layers of materials using an ultrasonic welding apparatus. The ultrasonic welding apparatus utilizes a sonotrode to perform a weld between at least the top and intermediate layer of the multi-layer member. Then, either the multi-layer member or the ultrasonic welding apparatus is rotated such that the bottom layer is positioned adjacent the sonotrode wherein the sonotrode forms a weld between at least the bottom layer and intermediate layer of the multi-layer member. The apparatus includes an ultrasonic welding gun having a C-shape frame including a base portion and a head portion. An ultrasonic welding device, including a sonotrode, is secured to the head portion and an anvil secured to the base portion. The ultrasonic welding gun is connected to a robot operative to position the ultrasonic welding gun to perform the welding operation.

Apparatus and method for joining layers of materials

An apparatus for ultrasonically welding workpieces that reduces sonotrode adhesion during the ultrasonic welding process. The sonotrode tip has a specific surface configuration, including a curvilinear shaped outer surface combined with a plurality of grooves and lands. Due to the curvilinear surface, the depth of the grooves gradually decreases near the outer edge or periphery of a contact surface of the sonotrode tip. Further, such a groove and land combination also provides a sharp edge or corner that reduces sliding of the tip on the workpiece and correspondingly reduces sticking. In addition, various types of coatings or inserts may also be used to reduce sticking of the sonotrode tip to the workpiece.

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Bloomfield Hills, MI, United States of America

Arnon Wexler