Reconfigurable, fixtureless manufacturing system and method assisted by learning software

An artificial intelligence (“AI”) assisted reconfigurable manufacturing system comprising:

• a first material handling robot located at an assembly area, for handling a first part;
• a second material handling robot located at the assembly area, for handling a second part;
• a joining robot located at the assembly area;
• gripping elements associated with each of the first and second material handling robots;
• a machine vision system positioned to view at least a portion of the assembly area;
• a computer controller comprising one or more processors, one or more electronic storage devices, and executable software instructions including virtual datums and learning AI software, which when executed, configure the one or more processors to:
• command the first material handling robot to grasp said first part by way of a first material handling device and move the first part to a first location within the assembly area in view of the machine vision system;
• command the second material handling robot to grasp said second part by way of a second material handling device and move the second part to a second location within the assembly area in view of the machine vision system;
• while said first and second parts remain otherwise suspended within a three-dimensional open-air workspace and out of contact with any fixtures, work surfaces, jigs, and locators:
• command the machine vision system to perform an alignment scan of datums on the first part;
• command the machine vision system to perform an alignment scan of datums on the second part;
• compare the location of the datums from the alignment scan with virtual datums;
• command the first or second material handling robots, by way of the learning AI software, to cause the robot to move the first part into an assembly position relative to the second part;
• immobilize said first material handling robot and said second material handling robot by electronic command such that said first part remains in said assembly position and command the joining robot to join the first part to the second part to create a first subassembly;
• command the machine vision system to perform an inspection scan of the datums of first subassembly;
• compare the datums from the inspection scan of the first subassembly to the virtual datums to determine discrepancies;
• and
• update the location of the virtual datums to compensate for said discrepancies.

A fixtureless, artificial intelligence (“AI”) assisted reconfigurable manufacturing system, said system comprising:

• a number of material handling robots located at an assembly area, wherein said assembly area comprises an open-air three-dimensional space;
• a number of material handling devices, each of which is attached to one of the number of material handling robots, and each of which is configured to accommodate any of a number of differently shaped parts;
• a first machine vision component located on each of the material handling devices and configured to identify each of the number of differently shaped parts;
• a second machine vision component positioned to view the assembly area;
• a controller comprising one or more processors, one or more electronic storage devices, and executable software instructions stored on the one or more electronic storage devices, which when executed, configure the one or more processors to:
• command at least two of the number of material handling robots to each grasp a different particular one of the number of differently shaped parts;
• command each of at least two material handling robots to move the respective grasped parts to particular locations within the assembly area such that each of the grasped parts adjoins at least one other grasped part to form a subassembly;
• while the respective grasped parts remain otherwise suspended within the open-air three-dimensional space and out of contact with any fixtures, work surfaces, jigs, and locators:
• command the second machine vision component to perform an alignment scan of datums of each of the grasped parts while the grasped parts remain at said particular locations, wherein said datums are features of the grasped parts;
• immobilize each of the at least two material handling robots by electronic command;
• command the second machine vision component to perform an inspection scan of datums the subassembly while said at least two material handling robots remain immobilized;
• reject the subassembly if the inspection scan reveals a datum location different from the location of a corresponding virtual datum by more than a margin of error;
• and
• join each of the gasped parts to one another to complete the subassembly if the inspection scan reveals the locations of each of the datums to be within the margin of error of the locations of the corresponding virtual datums.

A system for automated, fixtureless manufacture of an article from parts, said system comprising:

• a user system;
• one or more automated manufacturing machines, at least some of which are configured for physically manipulating said parts and at least some of which comprise a tool for joining said parts to form said article;
• a machine vision system configured to collect visual data form a work area for said one or more automated manufacturing machines;
• a controller in electronic communication with each of said automated manufacturing machines, said machine vision system, and said user system, wherein said controller comprises software instructions stored on one or more electronic storage devices which when executed, configures one or more processors of said controller to:
• receive user input by way of said user system regarding said article to be formed by joining said parts;
• command at least one of said automated manufacturing machines configured for physically manipulating said parts to perform physical manipulation which places said parts within view of said machine vision system while said parts remain otherwise suspended;
• while said parts remain otherwise suspended and out of contact with any fixtures, work surfaces, jigs, and locators:
• command said machine vision system to perform a scan of said parts to identify features of said parts;
• determine areas of said parts for joining by comparing said identified features to nominal data measurements derived from said user input;
• command at least one of said automated manufacturing machines configured for physically manipulating said parts to perform further physical manipulation which places said parts into positions in accordance with said nominal data measurements;
• and
• command said automated manufacturing machines comprising a tool for joining said parts to join said parts at said areas to form said article.