US-12619242-B2 - Facility sensory system for monitoring, guiding, and protecting flexible modular platforms moving through an assembly line

Abstract

A facility-based sensory system for the manufacture of modular vehicle subassemblies (MVSs) includes facility-based sensors and zone controllers. Each of the facility-based sensors is configured to be in communication with and transmit proximity data and/or vision data to the zone controllers. And each of the zone controllers is configured to be assigned to one of a plurality of assembly zones along an assembly line such that a MVS moving through the plurality of assembly zones is detected by the plurality of facility-based sensors and the detection is transmitted to the plurality of zone controllers. An onboard controller is included and configured to be attached to the MVS moving through the plurality of assembly zones. The onboard controller is configured to receive instructions from the plurality of zone controllers such that monitoring and directing of the MVS moving through the plurality of assembly zones is provided.

Inventors

• Galen Keith Thomas
• Kerry Lance Paskell

Assignees

• FORD GLOBAL TECHNOLOGIES, LLC

Dates

Publication Date

20260505

Application Date

20210202

Claims (20)

1. 1 . A facility-based sensory system for manufacture of modular vehicle subassemblies (MVSs), the system comprising: a plurality of facility-based sensors configured to detect proximity data or vision data associated with an MVS moving through a transition zone disposed between a first assembly zone and a second assembly zone, and wherein the plurality of facility-based sensors is configured to transmit the proximity data or the vision data to at least one of a plurality of zone controllers; and an onboard controller configured to be attached to the MVS, wherein the onboard controller establishes a communication link with a first zone controller of the plurality of zone controllers in response to being located at a predefined distance from a zonal boundary associated with the second assembly zone based on the proximity data or the vision data received from one or more sensors of the plurality of facility-based sensors configured as proximity sensors and positioned in the transition zone, and wherein the onboard controller terminates a communication link with a second zone controller of the plurality of zone controllers in response to the establishment of the communication link with the first zone controller, and further wherein the first zone controller is associated with the second assembly zone and the second zone controller is associated with the first assembly zone.
2. 2 . The system according to claim 1 , wherein the at least one of proximity data and vision data comprises at least one of geometric data, thermal data, acoustic data, vibrational data, and optical data.
3. 3 . The system according to claim 1 , wherein the plurality of facility-based sensors comprises at least one vision sensor array configured to transmit pathway alignment vision data on the MVS moving through at least one of the plurality of assembly zones.
4. 4 . The system according to claim 1 , wherein the plurality of facility-based sensors comprises at least one proximity sensor array configured to transmit at least one of pathway alignment data on the MVS moving through one of the plurality of assembly zones, detection data on the MVS entering one of the plurality of assembly zones, tracking data on the MVS moving through one of the plurality of assembly zones, distance data on the MVS approaching one of the plurality of assembly zones, distance data on the MVS leaving one of the plurality of assembly zones, speed data on at least one object approaching the MVS, location data on at least one object approaching the MVS, and distance data between at least one object and the MVS in one of the plurality of assembly zones, and wherein being located at the predefined distance from the zonal boundary associated with the second assembly zone is based upon the at least one proximity sensor transmitting detection data corresponding to the MVS being located at the predefined distance.
5. 5 . The system according to claim 1 , wherein the plurality of facility-based sensors comprises: at least one vision sensor array configured to transmit pathway alignment vision data on the MVS located in one of the plurality of assembly zones; and at least one proximity sensor array configured to transmit at least one of pathway alignment data on the MVS moving through one of the plurality of assembly zones, detection data on the MVS entering one of the plurality of assembly zones, tracking data on the MVS moving through one of the plurality of assembly zones, distance data on the MVS approaching one of the plurality of assembly zones, distance data on the MVS leaving one of the plurality of assembly zones, speed data on at least one object approaching the MVS, location data on at least one object approaching the MVS, and distance data between at least one object and the MVS in one of the plurality of assembly zones.
6. 6 . The system according to claim 1 , wherein each of the plurality of zone controllers is configured to receive the at least one of the proximity data and vision data and transmit at least one command to the onboard controller of the MVS in response to the received at least one of the proximity data and vision data.
7. 7 . The system according to claim 1 , wherein the system further comprises: the transition zone being positioned between a first sensor array and a second sensor array of the plurality of facility-based sensors, wherein the first sensor array is associated with the second assembly zone and the second sensor array is associated with the first assembly zone, and wherein: the first sensor array and the second sensor array are configured to monitor the MVS moving from the first assembly zone to the second assembly zone, and at least one of the first sensor array and the second sensor array detects the at least one of proximity data and vision data based on monitoring the MVS moving from the first assembly zone to the second assembly zone.
8. 8 . The system according to claim 6 , wherein the at least one command is at least one MVS operational command, and wherein the at least one MVS operation command is at least one of a path alignment command, a tracking command, and an obstacle avoidance command for the MVS moving through one of the plurality of assembly zones.
9. 9 . The system according to claim 1 , wherein the plurality of facility-based sensors are configured to wirelessly transmit the at least one of proximity data and vision data to the plurality of zone controllers.
10. 10 . The system according to claim 1 , wherein each of a plurality of transient data sensors is configured to transmit at least one of performance data, trouble code data, assembly testing data, and proximity data on the MVS moving through one of the plurality of assembly zones.
11. 11 . The system according to claim 10 , wherein the performance data on the MVS comprises performance data from at least one of a propulsion system, a steering system, a braking system, and a suspension system of the MVS moving through one of the plurality of assembly zones.
12. 12 . The system according to claim 1 , wherein a plurality of transient data sensors are configured to wirelessly transmit the transient data to the onboard controller.
13. 13 . The system according to claim 1 further comprising a central management system configured to receive data from the plurality of zone controllers and transmit at least one MVS command to each of the plurality of zone controllers, wherein the at least one MVS command is a response to the data received from the plurality of zone controllers.
14. 14 . The system according to claim 13 , wherein the plurality of zone controllers are each configured to transmit the at least one MVS command to the onboard controller of the MVS moving through one of the plurality of assembly zones.
15. 15 . The system according to claim 14 , wherein the central management system is configured to coordinate movement of a plurality of MVSs moving through the plurality of assembly zones.
16. 16 . A facility-based sensory system for manufacture of modular vehicle subassemblies (MVSs), the system comprising: a plurality of facility-based sensors assigned to a plurality of assembly zones such that each of the plurality of assembly zones has at least one of the plurality of facility-based sensors assigned thereto, wherein the plurality of facility-based sensors is configured to detect proximity data or vision data associated with an MVS moving through a transition zone disposed between a first assembly zone and a second assembly zone; a plurality of zone controllers assigned to the plurality of assembly zones such that each of the plurality of assembly zones has at least one of the plurality of zone controllers assigned thereto, wherein each of the plurality of facility-based sensors assigned to a given assembly zone is configured to be in communication with and transmit the proximity data or the vision data to at least one of the plurality of zone controllers assigned to the given assembly zone; and a plurality of transient data sensors and an onboard controller configured to be attached to the MVS, wherein each of the plurality of transient data sensors is configured to transmit transient signals from the MVS to the onboard controller, and the onboard controller establishes a communication link with a first zone controller of the plurality of zone controllers in response to being located at a predefined distance from a zonal boundary associated with the second assembly zone based on the proximity data or the vision data received from one or more sensors of the plurality of facility-based sensors configured as proximity sensors and positioned in the transition zone, and wherein the onboard controller terminates a communication link with a second zone controller of the plurality of zone controllers in response to the establishment of the communication link with the second assembly zone, and further wherein the first zone controller is associated with the second assembly zone and the second zone controller is associated with the first assembly zone, and wherein the onboard controller is configured to receive the transient signals and transmit transient data to the first zone controller or the second zone controller such that manufacturing information on the MVS moving through the plurality of assembly zones is detected and transmitted.
17. 17 . The system according to claim 16 , wherein the plurality of facility-based sensors comprises at least one of: a plurality of vision sensor arrays configured to transmit pathway alignment vision data on the MVS moving through the plurality of assembly zones; and a plurality of a proximity sensor arrays configured to transmit at least one of pathway alignment data on the MVS moving through one of the plurality of assembly zones, detection data on the MVS entering one of the plurality of assembly zones, tracking data on the MVS moving through one of the plurality of assembly zones, distance data on the MVS approaching one of the plurality of assembly zones, distance data on the MVS leaving one of the plurality of assembly zones, speed data on at least one object approaching the MVS, location data on at least one object approaching the MVS, and distance data between at least one object and the MVS moving through the plurality of assembly zones.
18. 18 . The system according to claim 17 further comprising a central management system configured to receive data from the plurality of zone controllers and transmit at least one MVS command to each of the plurality of zone controllers, wherein the at least one MVS command is a response to the data received from the plurality of zone controllers, and the plurality of zone controllers are each configured to transmit the at least one MVS command to the onboard controller of the MVS moving through one of the plurality of assembly zones.
19. 19 . A facility-based sensory system for manufacture of modular vehicle subassemblies (MVSs), the system comprising: a plurality of facility-based sensors assigned to a plurality of assembly zones such that each of the plurality of assembly zones has at least one of the plurality of facility-based sensors assigned thereto, wherein the plurality of facility-based sensors is configured to detect proximity data or vision data associated with an MVS moving through a transition zone disposed between a first assembly zone and a second assembly zone; a plurality of zone controllers assigned to the plurality of assembly zones such that each of the plurality of assembly zones has at least one of the plurality of zone controllers assigned thereto, wherein each of the plurality of facility-based sensors assigned to a given assembly zone is configured to be in communication with and transmit the proximity data or the vision data to at least one of the plurality of zone controllers assigned to the given assembly zone; a plurality of transient data sensors and an onboard controller configured to be attached to an MVS, wherein each of the plurality of transient data sensors is configured to transmit transient signals from the MVS to the onboard controller, and the onboard controller establishes a communication link with a first zone controller of the plurality of zone controllers in response to being located at a predefined distance from a zonal boundary associated with the second assembly zone based on the proximity data or the vision data received from one or more sensors of the plurality of facility-based sensors configured as proximity sensors and positioned in the transition zone, and wherein the onboard controller terminates a communication link with a second zone controller of the plurality of zone controllers in response to the establishment of the communication link with the second assembly zone, and further wherein the first zone controller is associated with the second assembly zone and the second zone controller is associated with the first assembly zone, and wherein the onboard controller is configured to receive the transient signals and transmit transient data to the first zone controller or the second zone controller such that manufacturing information on the MVS moving through the plurality of assembly zones is detected and transmitted; and a central management system configured to receive data from the plurality of zone controllers and transmit at least one MVS command to each of the plurality of zone controllers, wherein the at least one MVS command is a response to the data received from the plurality of zone controllers, and the plurality of zone controllers are each configured to transmit the at least one MVS command to the onboard controller of the MVS moving through one of the plurality of assembly zones.
20. 20 . The system according to claim 19 , wherein the plurality of facility-based sensors comprises: at least one vision sensor array configured to transmit pathway alignment vision data on the MVS located in one of the plurality of assembly zones; and at least one proximity sensor array configured to transmit at least one of pathway alignment data on the MVS moving through one of the plurality of assembly zones, detection data on the MVS entering one of the plurality of assembly zones, tracking data on the MVS moving through one of the plurality of assembly zones, distance data on the MVS approaching one of the plurality of assembly zones, distance data on the MVS leaving one of the plurality of assembly zones, speed data on at least one object approaching the MVS, location data on at least one object approaching the MVS, and distance data between at least one object and the MVS in one of the plurality of assembly zones.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and is a continuation-in-part of U.S. patent application Ser. No. 16/909,462 filed on Jun. 23, 2020, which is commonly assigned with the present application. This application is also related to co-pending applications filed concurrently herewith titled “FLEXIBLE MODULAR PLATFORM”, “METHOD OF VEHICLE ASSEMBLY INCLUDING MODULAR VEHICLE SUBASSEMBLY CONTROLS, COMMUNICATION AND MANUFACTURE”, “FLEXIBLE MODULAR PLATFORM PLANT NAVIGATION SYSTEM”, and “METHOD OF STORING, PROCESSING, AND TRANSMITTING DIGITAL TWINS FOR FLEXIBLE MODULE PLATFORMS AND VEHICLES”, which are commonly assigned with the present application. The contents of these patent applications are incorporated herein by reference in their entireties. FIELD The present disclosure relates to assembly lines and particularly to sensors on assembly lines. BACKGROUND The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. Vehicles are typically manufactured in assembly plants designed and built to support a projected vehicle assembly volume based on mechanical infrastructure requirements needed to support manufacturing operations. And such mechanical infrastructure requirements typically include conveyer systems and/or automatic guided vehicle (AGV) based systems to move vehicle subassemblies from station to station along an assembly line. However, the time, investment and capital expenditure needed to build conveyer systems or to adapt AGVs for specific application tasks can be prohibitive. These issues associated with assembly lines in vehicle assembly plants, among other issues related to manufacturing different product configurations in the same assembly facility, are addressed by the present disclosure. SUMMARY This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features. In one form of the present disclosure, a facility-based sensory system for the manufacture of modular vehicle subassemblies (MVSs) includes a plurality of facility-based sensors and a plurality of zone controllers. Each of the plurality of facility-based sensors is configured to be in communication with and transmit at least one of proximity data and vision data to at least one of the plurality of zone controllers. And each of the plurality of zone controllers is configured to be assigned to at least one of the plurality of assembly zones such that a MVS moving through the plurality of assembly zones is detected by the plurality of facility-based sensors and the detection transmitted to the plurality of zone controllers. An onboard controller is included and configured to be attached to the MVS moving through the plurality of assembly zones. In at least one variation of the present disclosure, the onboard controller is configured to receive the instructions from at least one of the plurality of zone controllers assigned to an assembly zone where the MVS is located such that at least one of monitoring of the MVS and directing the MVS moving through the plurality of assembly zones is provided. In some variations, the proximity data and/or vision data comprises at least one of geometric data, thermal data, acoustic data, vibrational data, and optical data. In at least one variation the plurality of facility-based sensors comprises at least one vision sensor array configured to transmit pathway alignment vision data on the MVS moving through at least one of the plurality of assembly zones. In the alternative, or in addition to, the plurality of facility-based sensors comprises at least one proximity sensor array configured to transmit at least one of pathway alignment data on the MVS moving through one of the plurality of assembly zones, detection data on the MVS entering one of the plurality of assembly zones, tracking data on the MVS moving through one of the plurality of assembly zones, distance data on the MVS approaching one of the plurality of assembly zones, distance data on the MVS leaving one of the plurality of assembly zones, speed data on at least one object approaching the MVS, location data on at least one object approaching the MVS, and distance data between at least one object and the MVS in one of the plurality of assembly zones. In some variations, each of the plurality of zone controllers is configured to receive the at least one of the proximity data and vision data and transmit at least one command to the onboard controller of the MVS in response to the received proximity data and/or vision data. In such variations the at least one command can be at least one MVS operational command and the least one MVS operational command can be at least one of a path alignment command, a tracking command, and an obstacle avoidance command for the MVS moving through one of the plurality of assembly zones. And in at least one variation, the plurality of f