Gm Global Technolgoy Operations, Inc.

Northwestern University

Shanghai Jiao Tong University

Hui-ping Wang

Blair E Carlson

Joshua L Solomon

Michael G Poss

David R Sigler

Bradley J Blaski

William P Payne

Michael J Karagoulis

Guangze Li

Lu Huang

Thomas Arthur Perry

Dalong Gao

David S Yang

Jian Cao

Chris A Ihrke

Scott E Parrish

Xiang Zhao

Wei Zeng

Wu Tao

Yu Pan

Amberlee S Haselhuhn

David A Gatny

Ping Guo

Sanja Laptosevic

Nannan Chen

Antonio R Vittorini

Baixuan Yang

Fenggui Lu

Vivian Vasquez

Haichao Cui

Zerun Ma

Yan Cai

Perry G Leggett

Aaron D Cox

Li Zuo

Paulina G Torres Guzman

Zixuan Wan

Dohyun Leem

A method of customizing a vehicle body includes inputting a selected customized embellishment to a laser controller, directing a beam of the laser onto a surface of the vehicle body, and guiding the beam of the laser with the laser controller to impart the selected customized embellishment to the surface.

Laser marking system for vehicle body customization

A laser brazing and welding system is disclosed and includes: a laser; a first cutting tool including a first cutting tip; and a control module. The control module is configured to control the laser to laser braze or laser weld two parts; and control ultrasonic vibration of the first cutting tip to remove one or more layers from at least one of the two parts prior to or subsequent to the laser brazing or laser welding of the two parts.

Ultrasonic pre-surface and post-surface processing for laser brazing and laser welding

Systems and methods for bending a material to a target resultant bending parameter using a bend forming tool are disclosed. The systems and methods receive values for parameters of properties of the material and of a bending process to be performed by the bend forming tool, creating or retrieving a calibration curve relating input bending parameter and resultant bending parameter based on the values from a database of calibration curves, determining a first springback compensated input bending parameter based on the target resultant bending parameter using the calibration curve, inputting the first springback compensated input bending parameter to the bend forming tool, and in a first step of bending the material, bending the material to the first springback compensated input bending parameter by applying the bending process using the bend forming tool.

Systems and methods for spingback compensation in bend forming processes

A robotic system for forming a moldable workpiece is provided. The robotic system includes a robot, an end effector, an adjustment module, and a control module. The robot is configured to pass the workpiece through a machine. The end effector is configured to be attached to the robot and configured to grasp and release the workpiece. The end effector is adjustable to a plurality of different configurations. The adjustment module is configured to determine a change in the workpiece from (a) a first form of the workpiece prior to the passing of the workpiece through the machine to (b) a second form of the workpiece after passing of the workpiece through the machine. The control module is configured to adjust a present configuration of the end effector to a second configuration based on the change in the workpiece from (a) the first form to (b) the second form.

Robotic system for free-forming a workpiece

A system for evaluating a rigidity of an angle bracket includes a test system having a first test fixture and a second test fixture. The system includes an angle bracket coupon including a first wall, a second wall coupled to the first wall at a bend to define an angle between the first wall and the second wall, and at least one three dimensional feature defined at the bend that extends between the first wall and the second wall. The angle bracket coupon is to be coupled to at least one of the first test fixture and the second test fixture to evaluate the rigidity of the angle bracket.

Systems and methods for evaluating rigidity of angle bracket

A system for inspecting a reflective surface includes a first imaging assembly configured to take a first image of the reflective surface. The first image includes depth information. The system also includes a second imaging assembly configured to take a second image of the reflective surface. The second image includes contrast information. The system further includes a processor configured to acquire the first image and the second image, estimate a depth profile of the surface based on the depth information, correlate the depth profile with the second image, and identify a feature of the reflective surface based on the correlation.

Inspection of reflective surfaces based on image correlation

Methods and systems for detecting weld defects, and methods for manufacturing vehicles using such methods or systems, are provided. An exemplary method includes receiving an input indicating a weld material and material thickness by a portable computing device and determining, with the portable computing device, a detection protocol for the weld material and material thickness. Further, the method includes communicating the detection protocol from the portable computing device to a portable heating source and to a portable thermographic sensor, heating a weld with the portable heating source according to the detection protocol, and recording thermographic data from the weld with the portable thermographic sensor according to the detection protocol. Also, the method includes communicating the thermographic data from the portable thermographic sensor to the portable computing device, and analyzing the thermographic data to detect whether the weld includes a defect and/or determine type, dimension and location of the defect.

Method and system for weld defect detection

A laser welded assembly and method of making. The laser welded assembly includes a first work piece having a thickness (T) defined between an external surface and a faying surface; a second work piece having a thickness (T) defined between an external surface and a faying surface of the second work piece; a weld seam having a core fusion zone extending from the external surface of the first work piece through the faying interface and at least partially into the thickness (T) of the second work piece; and a protruding fusion zone extending laterally from the core fusion zone adjacent to the external surface of the first work piece. The protruding fusion zone may be formed by post-heating or concurrently with the core fusion zone.

Laser welded assembly having a heat affected zone reinforcement and method of making the same

In accordance with an exemplary embodiment, a method is provided that includes: receiving an input as to a destination of travel for a vehicle; identifying, via a processor, a plurality of routes for the vehicle to travel to the destination; determining, via the processor, for each of the plurality of routes, a measure of difficulty of vehicle maneuvers for the vehicle to reach the destination via the route; and performing a vehicle action, via instructions provided by the processor, based on the respective measures of difficulty for the plurality of routes.

Navigation considering route driving difficulty

A flexible shelving unit includes a support frame having at least one vertical guide rack, the guide rack including an elongated slot. The shelf unit is supported by the guide rack. The shelf unit includes a shelf plate framed by a front reinforcement portion and by at least one side reinforcement portion. The shelf unit when in a release position is moved to selected upward and downward locations by vertical displacement of at least one locating pin connected to and extending from the at least one side reinforcement portion which is positioned and sliding within the elongated slot. A flat end face of the at least one side reinforcement portion directly contacts a plate face of the at least one vertical guide rack with the at least one side reinforcement portion and the shelf plate in a horizontal position to frictionally retain the shelf unit in the horizontal position.

Flexible shelving unit

A welding electrode includes a weld face that has a convex base weld face surface and a plurality of ringed ridges that are radially spaced apart on the base weld face surface and surround a central weld face axis. The plurality of ringed ridges including an innermost ringed ridge and an outermost ringed ridge. The innermost ringed ridge is located closest to the central weld face axis and rises above a central portion of the base weld face surface, and the outermost ringed ridge is located farthest from the central weld face axis and rises above an outer peripheral portion of the base weld face surface. At least one of the plurality of ringed ridges is a discontinuous ringed ridge.

Resistance welding electrode

A method of laser welding a workpiece stack-up () of overlapping steel workpieces () involves heat-treating a region () of the stack-up () followed by forming a laser weld joint () that is located at least partially within the heat-treated region (). During heat-treating, one or more pre-welding laser beams () are sequentially directed at a top surface () of the workpiece stack-up () and advanced along a pre-welding beam travel pattern () so as to reduce an amount of vaporizable zinc within the stack-up (). Thereafter, the laser weld joint () is formed by directing a welding laser beam () at the top surface () of the workpiece stack-up () and advancing the welding laser beam () along a welding beam travel pattern () that at least partially overlaps with a coverage area of a pre-welding beam travel pattern () or a shared coverage area portion of multiple pre-welding beam travel patterns (). The method can help reduce an amount of vaporizable zinc within the stack-up ().

Method for laser welding steel workpieces

A method of laser welding a workpiece stack-up that includes two or more overlapping aluminum alloy workpieces is disclosed. The method involves controlling the power level of the laser beam during at least one of an initial stage or a final stage of advancing the laser beam along a weld path so as to limit a line energy of the laser beam during such stage or stages to being no greater than 10% above a line energy of the laser beam during an intermediate stage of laser beam advancement that is performed between the initial and final stages. By limiting the line energy during the initial and/or final stages of laser beam advancement along the weld path, excessive fusion of the workpiece stack-up assembly can be avoided in those locations to help protect against hot-cracking in the resultant laser weld joint.

Avoiding hot cracks during laser welding of a workpiece stack-up assembly of aluminum alloy workpieces

A spot weld may be formed between an aluminum workpiece and an adjacent overlapping steel workpiece with the use of opposed spot welding electrodes that have mating weld faces designed for engagement with the outer surfaces of the workpiece stack-up assembly. The electrode that engages the stack-up assembly proximate the aluminum workpiece includes a central ascending convex surface and the electrode that engages the stack-up assembly proximate the steel workpiece has an annular surface. The mating weld faces of the first and second spot welding electrodes distribute the passing electrical current along a radially outwardly expanding flow path to provide a more uniform temperature distribution over the intended spot weld interface and may also produce a deformed bonding interface within the formed weld joint. Each of these events can beneficially affect the strength of the weld joint.

Mating electrodes for resistance spot welding of aluminum workpieces to steel workpieces

A method of laser welding a workpiece stack-up that includes two or three overlapping aluminum alloy workpieces involves constraining a free end of an overlapping portion of a first aluminum alloy workpiece against movement away from an underlying second aluminum alloy workpiece to counteract the thermally-induced forces that cause out-of-plane deformation of one or more of the aluminum alloy workpieces during laser welding. Such constraint of the free end of the first aluminum alloy workpiece may be accomplished by clamping, spot welding, or any other suitable practice. By constraining the free end of the first aluminum alloy workpiece, and thus inhibiting out-of-plane deformation of the aluminum alloy workpieces when laser welding is practiced in a nearby welding region, the occurrence of hot cracking is minimized or altogether eliminated in the final laser weld joint.

Growing community of inventors

Troy, MI, United States of America

Hui-ping Wang