Ford Global Technolgoies, LLC

Kerry Lance Paskell

Galen Keith Thomas

Jason Michael Moore

A method for verifying an alignment of one or more devices of a vehicle in a manufacturing environment includes selecting an alignment verification routine to be performed by an autonomous alignment verification mobile robot (AAVMR) and autonomously positioning the AAVMR based on a position of the vehicle and one or more displacements associated with the alignment verification routine. The method includes performing, using the AAVMR, the alignment verification routine to generate one or more alignment characteristics associated with the one or more devices and broadcasting a notification based on the one or more alignment characteristics.

Methods and systems for verifying the alignment of vehicle devices

A method of manufacturing a modular vehicle subassembly (MVS) includes assembling a propulsion system onto a vehicle frame, assembling a suspension system onto the vehicle frame, assembling a steering system and braking system onto the vehicle frame, assembling an electrical distribution system onto the vehicle frame, and integrating an onboard controller with the propulsion system, the steering system, and the braking system. The onboard controller is configured to command the propulsion system, the steering system, and the braking system such that the MVS is operable to move untethered through a top hat assembly line during assembly of a top hat on the MVS.

Method of vehicle assembly including modular vehicle subassembly controls, communication and manufacture

A manufacturing system includes a plurality of first autonomous mobile robots (AMRs), a plurality of second AMRs, and a central management system. Each first AMR transports a body from among multiple bodies for multiple vehicles, and each second AMR transports a chassis from multiple chassis for the multiple vehicles. The central management system is configured to direct the plurality of the first AMRs into a first assembly line process, direct the plurality of the second AMRs into a second assembly line process, and direct an identified second AMR of the plurality of the second AMRs to move behind an identified first AMR of the plurality of the first AMRs. The identified second AMR is transporting a selected chassis from among the plurality of chassis, the identified first AMR is transporting a selected body from among the plurality of bodies, and the selected body is associated with the selected chassis.

Method and system for a vehicle decking process associated with manufacturing a vehicle

A navigation system for remote control movement of modular vehicle subassemblies (MVSs) through a plurality of assembly zones of a vehicle assembly facility includes a predefined primary pathway configured for the MVSs to move along during assembly of top hats on the MVSs, a plurality of sensors, a plurality of zone controllers, and a central management system with a navigation algorithm. The plurality of sensors are configured to transmit at least one of proximity data and visual data on the MVSs moving through the plurality of assembly zones to the plurality of zone controllers. The central management system is configured to be in communication with each of the plurality of zone controllers and the navigation algorithm is configured to receive the at least one of proximity data and visual data and calculate movement instructions for remote control movement of the MVSs moving through the plurality of assembly zones.

Flexible modular platform plant navigation system

A method for creating a digital twin for a vehicle assembled on at least one assembly line includes assembly of a modular vehicle subassembly (MVS) in a plurality of MVS assembly zones by assembling at least one component at each MVS assembly zone, scanning the at least one component at each MVS assembly zone and acquiring scanned data, and storing the scanned data in a MVS temporary digital file assigned to the pre-assembled MVS. The method also includes updating a MVS permanently digital file assigned to the pre-assembled MVS after the at least one component at each of the MVS assembly zones has been assembled and storing the MVS permanent digital file when assembly of the MVS is complete.

Method of storing, processing, and transmitting digital twins for flexible module platforms and vehicles

A system for remote control of modular vehicle subassemblies within a vehicle assembly facility includes a central management system having predetermined assembly paths and specifications for the modular vehicle subassemblies and a zone management system having zone controllers in communication with the central management system and in communication with the onboard controllers of the modular vehicle subassemblies. The zone controllers are configured to receive transient data from the onboard controllers of the modular vehicle subassemblies and manage movement of the modular vehicle subassemblies throughout the zones within the vehicle assembly facility.

Remote controlled flexible modular platform system

A method includes positioning, by a robot, a servo press proximate one or more reference identifiers of the vehicle. The method includes applying, by the servo press, a known weight to the vehicle. The method includes calibrating the payload monitoring system of the vehicle based on data from a plurality of payload sensors in response to applying the known weight.

Systems and methods for calibrating a payload sensing system of a vehicle

A manufacturing system includes a first autonomous mobile robot (AMR), a second AMR, a first set of mobile robotic systems, and a central management system. The first AMR transports a body of a vehicle to an assembly area. The second AMR transports a chassis of the vehicle to the assembly area. The first set of mobile robotic systems is provided at the assembly area and moves the body. The central management system includes instructions to direct the first AMR transporting the body to the assembly area; direct the second AMR transporting the chassis to the assembly area; have the first set of mobile robotic systems lift the body from the first AMR; direct the first AMR to a secondary area; direct the second AMR to move to a desired position relative to the body; and instruct the first set of mobile robotic systems place the body on the chassis.

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Detroit, MI, United States of America

Kerry Lance Paskell