Method and apparatus for drilling a workpiece

Abstract

The present invention relates to a method and apparatus for drilling a workpiece, and provides a drilling end effector for drilling a workpiece having a workpiece surface. The drilling end effector includes a chuck configured to hold a drilling tool, and a nose frame configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nose frame includes an end portion. The nose frame includes at least one suction cup and at least one suction feed line. At least one suction cup is fluidically connected to at least one suction feed line. At least one suction feed line is configured to be fluidically connected to a suction system. At least one suction cup is configured to engage in physical contact with the workpiece surface and be pulled under the suction action of the suction system, so that at least one suction cup adheres to the workpiece surface, thereby maintaining the end portion of the nose frame on the workpiece surface.

Description

Background Art

[0001] The assembly, maintenance and repair of aircraft involve many drilling operations. For example, openings (e.g., holes, etc.) are drilled in aircraft components to accommodate fasteners (e.g., rivets, bolts, screws, etc.) during component assembly; and drills are used to remove existing fasteners so that damaged, worn and / or structurally damaged components can be replaced. Many drilling operations are now automated, such as using gantry drilling systems, column drilling systems, or articulated robotic arms. Recently, the versatility and flexibility provided by articulated robotic arms have increased their popularity, particularly in areas with limited space for performing drilling operations. However, articulated robotic arms have limited stiffness along the length of the arm. Therefore, when a load applied to a component (e.g., during a drilling operation, etc., via the engagement of a drilling end effector with a component surface) is transmitted (e.g., applied, protruded, etc.) to the joint of the articulated robotic arm, the arm can bend, thereby moving the drilling tool along the surface of the component (e.g., sliding, sliding, sliding, etc.), away from the target drilling location. For example, such movement of the drilling tool along the surface of the component away from the target drilling location may prevent the opening from being drilled at the exact location, may damage (e.g., scratch, scrape, score, etc.) the component and / or other structures (e.g., attached substructures, etc.), and / or may increase the breakage rate of the drill bit.

[0002] One known method of correcting the undesired movement of a drilling tool along a component surface is to use an auxiliary encoder that measures the deflection of a joint of a manipulator. The measured deflection is fed from the auxiliary encoder to a manipulator control system that uses the deflection to correct any movement of the drilling tool away from the target drilling position. However, mounting the auxiliary encoder on the manipulator increases the complexity of the manipulator and increases the cost of manufacturing, assembling and maintaining an articulated manipulator. Laser tracking systems are also known for correcting the movement of a drilling tool away from a target drilling position by measuring the tool center point (TCP) of an articulated manipulator. However, such laser tracking systems require relatively accurate calibration of the tracking system, a rigid fixture, and a camera with the ability to detect the measurement target, each of which increases the cost and complexity of the drilling system (e.g., of the articulated manipulator, of the automation unit in which the drilling operation is performed, of the control system, etc.). Other known methods for correcting the undesired movement of a drilling tool include a normal sensor that measures whether the drilling tool is perpendicular to the component surface. However, adding a normal sensor increases the cost and complexity of the drilling system. Summary of the invention

[0003] In one aspect, a drilling end effector for drilling a workpiece having a workpiece surface is provided. The drilling end effector includes a chuck configured to hold a drilling tool, and a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion. The nosepiece includes at least one suction cup and at least one suction feed line. The at least one suction cup is fluidly connected to the at least one suction feed line. The at least one suction feed line is configured to be fluidly connected to a suction system. The at least one suction cup is configured to engage in physical contact with the workpiece surface and be pulled under the suction action of the suction system so that the at least one suction cup adheres to the workpiece surface, thereby holding the end portion of the nosepiece on the workpiece surface.

[0004] On the other hand, a drilling system for drilling a workpiece having a workpiece surface is provided. The drilling system includes a drilling platform and a drilling end effector configured to be held by the drilling platform. The drilling end effector includes a chuck configured to hold a drilling tool, and a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion. The nosepiece includes at least one suction cup and at least one suction feed line. The at least one suction cup is fluidly connected to the at least one suction feed line. The at least one suction feed line is configured to be fluidly connected to a suction system. The at least one suction cup is configured to engage in physical contact with the workpiece surface and be pulled under the suction action of the suction system so that the at least one suction cup adheres to the workpiece surface, thereby holding the end portion of the nosepiece on the workpiece surface.

[0005] On the other hand, a drilling end effector for drilling a workpiece having a workpiece surface is provided. The drilling end effector includes a chuck configured to hold a drilling tool, and a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion, the end portion including an end face, the end face being configured to face the workpiece surface during drilling of the workpiece. The nosepiece includes at least one suction feed line. The end face of the end portion of the nosepiece includes at least one suction cup. At least one suction cup is fluidly connected to at least one suction feed line. At least one suction feed line is configured to be fluidly connected to a suction system. The nosepiece also includes a suction tube configured to collect hole chips during drilling of the workpiece. At least one suction cup is configured to engage in physical contact with the workpiece surface and be pulled under the suction action of the suction system, so that at least one suction cup adheres to the workpiece surface, thereby maintaining the end portion of the nosepiece on the workpiece surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 Schematic diagram showing a drilling system according to one embodiment.

[0007] Figure 2 for Figure 1A perspective view of a portion of a drilling system is shown illustrating a drilling end effector according to one embodiment.

[0008] Figure 3 is a schematic diagram showing a pattern end effector held by a drilling platform of a drilling system according to one embodiment.

[0009] Figure 4 A plan view of a pattern applied to a surface of a workpiece according to one embodiment is shown.

[0010] Figure 5 for Figure 4 A plan view of an area of ​​a workpiece surface shown in , showing a nose of a drilling end effector that is misaligned with a pattern according to one embodiment.

[0011] Figure 6 for Figure 4 and Figure 5 A plan view of a region of a workpiece surface is shown showing a nose bridge aligned with a pattern according to one embodiment.

[0012] Figure 7 The present invention is a flow chart showing a method for drilling a workpiece according to one embodiment.

[0013] Figure 8 Schematic diagram showing a drilling system according to one embodiment.

[0014] Fig. 9 for Figure 8 A perspective view of a portion of a drilling system is shown illustrating a drilling end effector according to one embodiment.

[0015] Fig.10 According to one embodiment Figure 8 A bottom plan view of the end portion of the nosepiece of the drilling end effector is shown.

[0016] Fig.11 A partially cut-away front view showing the structure, arrangement, etc. of a suction cup according to an embodiment.

[0017] Fig.12 A partially cut-away front view showing the structure, arrangement, etc. of a suction cup according to another embodiment.

[0018] Fig.13 The partially cut-away front view shows the structure, arrangement, etc. of a suction cup according to yet another embodiment.

[0019] Fig.14 A bottom plan view showing the construction, arrangement, etc. of a suction feed line according to one embodiment.

[0020] Fig.15 A schematic diagram of one embodiment of an aircraft is shown.

[0021] Fig.16 A block diagram of one embodiment of an aircraft production and service method. DETAILED DESCRIPTION

[0022] When read in conjunction with the accompanying drawings, the following detailed description of the aforementioned summary of the invention and certain embodiments and implementations will be better understood. As used herein, an element or step in the singular and beginning with the phrase "one" or "an" should be understood as not necessarily excluding multiple elements or steps. In addition, reference to "an embodiment" or "an implementation" is not intended to be interpreted as excluding the existence of other embodiments and implementations that also include the features. In addition, unless explicitly stated to the contrary, an embodiment that "includes" or "has" an element or multiple elements with a specific characteristic may include other elements that do not have the characteristic.

[0023] Although various spatial and directional terms such as "top", "bottom", "upper", "lower", "vertical", etc. are used to describe the embodiments and implementations of the present disclosure, it should be understood that these terms are used only with respect to the orientation shown in the drawings. The orientation can be reversed, rotated, or otherwise changed, so that if the structure is flipped 180 degrees, the top side will become the bottom side; if the structure is pivoted 90 degrees, it will become the left or right side, and so on.

[0024] Certain embodiments of the present disclosure provide a drilling system for drilling a workpiece. The drilling system includes a pattern generator configured to apply a pattern on a workpiece surface of a workpiece at a reference position relative to a target drilling position. The drilling system includes a drilling end effector, which includes a chuck configured to hold a drilling tool. The drilling end effector also includes a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion configured to be held on the workpiece surface of the workpiece. The drilling end effector also includes a camera configured to acquire an image of an area of ​​the workpiece surface including the pattern. The image acquired by the camera indicates whether the end portion of the nosepiece is aligned with the pattern on the workpiece surface.

[0025] Certain embodiments of the present disclosure help align a drilling tool with a target drilling location on a workpiece surface. Certain embodiments of the present disclosure help detect, reduce and / or correct movement (e.g., slipping, sliding, sliding over, etc.) of a drilling tool away from a target drilling location on a workpiece surface, for example, before performing a drilling operation on the workpiece.

[0026] Certain embodiments of the present disclosure reduce the occurrence of drilling openings at inaccurate locations on the surface of a workpiece (e.g., openings that are not aligned with a target drilling location, etc.). Certain embodiments of the present disclosure reduce damage (e.g., scraping, shaving, scratching, etc.) to a workpiece and / or other structures (e.g., attached substructures, etc.) caused by movement of a drilling tool along the surface of the workpiece. Certain embodiments of the present disclosure reduce the number of broken drilling tools caused by repeated drilling operations. Certain embodiments of the present disclosure help detect, prevent, reduce and / or correct the movement of a drilling tool away from a target drilling location (e.g., sliding, slipping, sliding over, etc.) without increasing the cost and / or complexity of one or more components of the drilling system (e.g., an articulated robotic arm, a drilling end effector, an automated unit that performs drilling operations, a control system, etc.). For example, certain embodiments of the present disclosure utilize the capabilities of an existing camera on a drilling end effector.

[0027] Now referring to the accompanying drawings, Figure 1 A schematic diagram of a drilling system 100 is provided in FIG. The drilling system 100 includes a drilling platform 102, a pattern generator 104, and a drilling end effector 106. As will be described in more detail below, the pattern generator 104 is configured to apply a pattern (e.g., Figure 3 and Figure 5 and the camera 114 of the drilling end effector 106 is configured to acquire one or more images indicating whether the drilling end effector 106 is aligned with the pattern on the workpiece surface 110.

[0028] Reference now Figure 1 and Figure 2 , the drilling end effector 106 includes a base 116 and a chuck 118. The base 116 of the drilling end effector 106 is configured to be held by the drilling platform 102. The chuck 118 is held by the base 116 so that the chuck 118 is configured to rotate relative to the base 116 about the rotation axis 120 during operation of the drilling system 100 (e.g., drilling a hole in the workpiece 112, etc.). The drilling end effector 106 includes any suitable drive mechanism (not shown) that is operably connected to the chuck 118 for driving the chuck 118 to rotate about the rotation axis 120 (i.e., for applying a torque on the chuck 118 to rotate the chuck 118 about the rotation axis 120), such as but not limited to an electric motor, a manual crank, an internal combustion engine, etc. The chuck 118 is Figure 2 Not visible in.

[0029] The chuck 118 is configured to hold a drilling tool 122 such that a rotational axis 120 of the chuck 118 is aligned with a centerline axis 124 of the drilling tool 122. The drilling tool 122 is fixed to the chuck 118 such that the drilling tool 122 is configured to rotate with the chuck 118 about the rotational axis 120 and about the centerline axis 124. Specifically, the drilling tool 122 may be rigidly fixed to the chuck 118 such that the chuck 118 transmits torque provided by the drive mechanism to the drilling tool 122, thereby rotating the drilling tool 122 about the rotational axis 120 and the centerline axis 124. In some examples, the chuck 118 is configured to releasably hold the drilling tool 122 such that the drilling tool 122 may be selectively fixed to and removed from the drilling end effector 106, such as for repair or replacement of the drilling tool 122, and / or for maintenance, storage, movement, maintenance of the drilling end effector 106, etc. Drilling tools 122 Figure 2 Not visible in.

[0030] In the operation of drilling the hole end effector 106 into the workpiece surface 110, the drilling tool 122 rotates about the axes 120 and 124 in a cutting direction (e.g., clockwise, counterclockwise, etc.) that enables the drilling tool 122 to cut into the workpiece surface 110. As the drilling tool 122 rotates about the axes 120 and 124 in the cutting direction, the drilling tool 122 moves toward (e.g., in the direction of arrow 126, etc.) the workpiece surface 110 along the axes 120 and 124 and makes physical contact with it. The drilling tool 122 is forced against (e.g., pressed into, etc.) the workpiece surface 110 along the axes 120 and 124 (e.g., in the direction of arrow 126, etc.) to provide a contact force between the drilling tool 122 and the workpiece surface 110. The rotation of the drilling tool 122 in the cutting direction and the contact force between the drilling tool 122 and the workpiece surface 110 cause the drilling tool 122 to cut (e.g., drill, etc.) into the workpiece surface 110.

[0031] The drilling end effector 106 includes a nosepiece 128 mounted to the base 116. Specifically, the nosepiece 128 extends a length from an end portion 130 to an opposite end portion 132. The end portion 130 of the nosepiece 128 is mounted to the base 116 of the drilling end effector 106 so that when the drilling tool 122 is held by the chuck 118, the nosepiece 128 at least partially surrounds the circumference of the drilling tool 122, such as Figure 1 and Figure 2 As shown. Figure 1 and Figure 2 As shown, when the nosepiece 128 is mounted to the base 116 of the drilling end effector 106, the length of the nosepiece 128 extends along the axes 120 and 124. Figure 1, the base 116 and the nose piece 128 are cut away so that the interior of the base 116 and the nose piece 128 can be seen to show the chuck 118 and the drilling tool 122.

[0032] The end portion 130 of the nosepiece 128 is rigidly mounted to the base 116 of the nosepiece 128 such that the nosepiece 128 remains stationary relative to the base 116 (i.e., does not rotate with the drilling tool 122 about the axes 120 and 124) during operation of the drilling system 100. In other words, during operation of the drilling system 100, the drilling tool 122 rotates relative to the base 116 and the nosepiece 128 of the drilling end effector 106 about the rotational axis 120 and the centerline axis 124. The end portion 130 of the nose bridge 128 is mounted to the base 116 using any method, device, structure, mechanism, manner, arrangement, connection, connector, device, etc. (such as, but not limited to, adhesive, interference fit, snap fit, fasteners (e.g., threaded fasteners, etc.), latches, welds, brazing, epoxies, clips, rings, cotter pins, quick release pins, clevises, clevis type connections, bayonet connections, spring overrides, etc.) that enables the nose bridge 128 to function as described and / or shown herein.

[0033] As will be described in more detail below, the end portion 132 of the nosepiece 128 is configured to be aligned with the centerline axis 124 of the drilling tool 122 and a target drilling location (eg, Figure 4-6 The nosepiece 128 is held on the workpiece surface 110 at a position aligned with a target drilling position 136 shown in FIG. 1 , etc. The end portion 132 of the nosepiece 128 includes an end face 134 that is configured to face the workpiece surface 110 of the workpiece 112 when the end portion 132 is held on the workpiece surface 110 (e.g., during drilling of the workpiece 112, etc.). In some embodiments, the end face 134 is configured to engage in physical contact with the workpiece surface 110 of the workpiece 112, for example, to help hold the end portion 132 on the workpiece surface 110.

[0034] The nosepiece 128 includes any structure, configuration, arrangement, geometry, etc. that enables the nosepiece 128 to function as described and / or illustrated herein (e.g., to facilitate alignment of the drilling tool 122 with a target drilling location on the workpiece surface 110, etc.). In the embodiment illustrated herein, the end portion 132 of the nosepiece 128 is defined by a single continuous segment that continuously surrounds (e.g., surrounds approximately an entire circumference, etc.) the drilling tool 122, such as from Figure 2 , Figure 5 and Figure 6Although shown as including a circle, the end portion 132 of the nose bridge 128 additionally or alternatively includes one or more other shapes, such as, but not limited to, a polygon, a rectangle, a triangle, a quadrilateral, another curved shape, an ellipse, a hexagon, an octagon, etc.

[0035] Any other suitable structure of the end portion 132 that enables the nosepiece 128 to function as described and / or shown herein is considered to be within the scope of the present disclosure. For example, in some other embodiments, the end portion 132 of the nosepiece 128 is defined by any number of discrete segments, each of which extends only around a portion of the circumference of the drilling tool 122 (e.g., any number of discrete legs extending outwardly from the end portion 130, etc.).

[0036] In the exemplary embodiments shown herein, the workpiece surface 110 is substantially flat along the region including the target drilling location. In other embodiments where the region of the workpiece surface 110 including the target drilling location includes a 3D shape (e.g., contoured, etc.), the end portion 132 (e.g., end face 134, etc.) can include a 3D shape that is complementary to the 3D shape of the region of the workpiece surface 110 including the target drilling location (e.g., as opposed to the approximately flat geometry of the end face 134 of the embodiments shown herein, etc.).

[0037] The nosepiece 128 optionally includes a suction tube 138 configured to collect debris generated during a drilling operation (e.g., during drilling of the workpiece 112, etc.). The suction tube 138 is configured to be in fluid communication with a suction system (not shown) configured to generate suction within the suction tube 138 that enables the suction tube 138 to collect the debris.

[0038] In the embodiments described herein, Figure 1 and Figure 2As shown, the drilling platform 102 is an articulated robotic arm 102a, which is configured to, for example, hold a drilling end effector 106 on an end portion 140 of the articulated robotic arm 102a. The articulated robotic arm 102a of the exemplary embodiment provides a fully automated drilling system 100. For example, the articulated robotic arm 102a is configured to automatically move the drilling end effector 106 to a target drilling position on a workpiece surface 110, and activate the drilling end effector 106 to drill into the workpiece 112 using a drilling tool 122. The drilling system 100 includes a control system 142, which is operably connected (e.g., using a wired and / or wireless connection, etc.) to the articulated robotic arm 102a and / or the end effector 106 or incorporated as a component of the articulated robotic arm 102a and / or the end effector 106 to control the drilling system 100. For example, the control system 142 is configured to control the movement of the articulated robotic arm 102 a , the initiation of the drilling end effector 106 drilling into the workpiece 112 , other control functions of the drilling system 100 , and the like.

[0039] The drilling platform 102 is not limited to an articulated robotic arm 102a. Rather, additionally or alternatively, the drilling system 100 includes any other type of drilling platform (whether the drilling system 100 is fully automated, semi-automated, or fully manual), such as but not limited to a drill press, a fixture and / or other structure (e.g., a suspended structure, a structure mounted on the workpiece 112, a structure adjacent to the workpiece 112, a structure resting on and / or attached to the floor, etc.), a gantry drilling platform, a column drilling platform, a handheld drilling platform (e.g., a handheld battery, cord, pneumatic or hydraulic powered drill, etc.), a less portable drilling device, etc.

[0040] In some embodiments, such as but not limited to, in the exemplary embodiment shown herein, the chuck 118 and the drilling tool 122 held thereby are moved relative to the drilling platform 102 and the base 116 of the drilling end effector 106 to move the drilling tool 122 toward and into physical contact with the workpiece surface 110 along axes 120 and 124 (e.g., in the direction of arrow 126, etc.); and the contact force between the drilling tool 122 and the workpiece surface 110 is provided by applying a force on the chuck 118, thereby causing the drilling tool 122 to press the drilling tool 122 against the workpiece surface 110.

[0041] The drilling system 100 includes any suitable mechanism, structure, etc., such as, but not limited to, mechanical sleeves, bearings, etc., that enables the chuck 118 and the drilling tool 122 to move relative to the drilling platform 102 and the base 116 of the drilling end effector 106 along the axes 120 and 124. The movement of the chuck 118 and the forces exerted on the chuck 118 and thus on the drilling tool 122 to move the drilling tool 122 relative to the drilling platform 102 and the base 116 toward the workpiece surface 110 and provide a contact force between the drilling tool 122 and the workpiece surface 110 are fully automated in an exemplary embodiment, for example, using electric, hydraulic, and / or pneumatic linear actuators controlled by a control system 142 or the like. In some other embodiments, the movement of the chuck 118 and the forces applied to the chuck 118 to move the drilling tool 122 relative to the drilling platform 102 and the base 116 toward the workpiece surface 110 and provide contact forces between the drilling tool 122 and the workpiece surface 110 are: (1) assisted (e.g., semi-automated, etc.) using, for example, hydraulic cylinders, pneumatic cylinders, gas springs, etc.; or (2) fully manual, such as by an operator who directly and / or indirectly applies forces on the drilling tool 122 (e.g., using a hand crank, handle, drill press, etc.) to perform all operations. In the exemplary embodiment of the drilling end effector 106 shown herein, the nose 128 is rigid along its length so that the drilling tool 122 can be moved toward the workpiece surface 110 along the length of the nose 128 (i.e., relative to the length of the nose 128).

[0042] An example of a fully automated implementation includes the exemplary implementation of the articulated robotic arm 102a shown herein, wherein the drilling platform 102 includes an implementation of a drill press, gantry, or column system that includes a linear actuator (not shown) that automatically moves a drilling tool 122 relative to a base 116 of a drilling end effector 106, for example, upon activation by an operator and / or a control system, and automatically applies a force on the drilling tool 122 that provides a contact force between the drilling tool 122 and the workpiece surface 110. An example of a semi-automated implementation is an implementation in which the drilling platform 102 is a handheld platform that includes a linear actuator and / or other mechanism that is configured to automatically move the drilling tool 122 relative to a base 116 of a drilling end effector 106 to automatically apply a force on the drilling tool 106 that provides a contact force, for example, upon activation by an operator holding the drilling platform 102. Examples of manual systems include an embodiment in which the drilling platform 102 is a drill press including a manual crank that can be manually turned by an operator to indirectly move the drilling tool 122 relative to the base 116 and indirectly exert a force on the drilling tool 122 that provides a contact force between the drilling tool 122 and the workpiece surface 110.

[0043] In some other embodiments, the drilling platform 102 and the base 116 of the drilling end effector 106 are: (1) moved toward the workpiece surface 110 along the axes 120 and 124 (e.g., in the direction of arrow 126, etc.), thereby causing the drilling tool 122 to move toward the workpiece surface 110 and make physical contact therewith; and (2) exerting a force on the base 116 of the drilling end effector 106 to press the drilling tool 122 against the workpiece surface 110, thereby providing a contact force between the drilling tool 122 and the workpiece surface 110. The movement of the base 116 of the drilling end effector 106 and the force applied to the base 116 of the drilling end effector 106 to move the drilling tool 122 toward the workpiece surface 110 and provide a contact force between the drilling tool 122 and the workpiece surface 110 are: (1) fully automated in certain embodiments; (2) assisted in certain embodiments (e.g., semi-automated, etc.); and (3) fully manual in certain embodiments (e.g., fully performed by an operator, etc.). Examples of fully automated embodiments include an embodiment in which an articulated robotic arm (e.g., the articulated robotic arm 102a, etc.) automatically moves the base 116 of the drilling end effector 106 to move the drilling tool 122 toward the workpiece surface 110 and provide a contact force between the drilling tool 122 and the workpiece surface 110. Examples of manual embodiments include embodiments in which an operator holding the drilling platform 102 manually moves the drilling platform 102, thereby moving the base 116 of the drilling end effector 106, thereby moving the drilling tool 122 toward the workpiece surface 110, and manually applies a force to the drilling platform 102 and the base 116 that provides a contact force between the drilling tool 122 and the workpiece surface 110. In some embodiments in which the base 116 of the drilling end effector 106 is moved to move the drilling tool 122 toward the workpiece surface 110 and provide a contact force between the drilling tool 122 and the workpiece surface 110, the nose piece 128 is foldable (e.g., elastically, non-elastically, etc.) along its length to enable the drilling tool 122 to extend beyond the end portion 132 of the nose piece 128 while the nose piece 128 remains on the workpiece surface 110 during the drilling operation.

[0044] In the exemplary embodiment shown herein, the drilling tool 122 is a drill bit, and more specifically a twist drill bit. However, the drilling tool 122 may additionally or alternatively include any type of drill bit, such as but not limited to a step drill bit, a loose drill bit, a hole saw, a center and positioning drill bit, a core drill bit, a countersink drill bit, an ejection drill bit, a gun drill bit, an indexable drill bit, a left-hand drill bit, a metal spade bit, a straight groove drill bit, a drill machine, a lip tooth bone drill bit, a wood spade drill bit, a spoon drill bit, a Forstner drill bit, a center drill bit, a spiral drill bit, a small drill bit, a hinge countersink drill bit, an adjustable wood drill bit, a metal drill bit, a diamond core drill bit, a masonry drill bit, a glass drill bit, a PCB through-hole drill bit, a mounting drill bit, a fishing drill bit, a flexible shaft drill bit, etc. Moreover, the drilling tool 122 is not limited to including a drill bit. Instead, the drilling tool 122 may additionally or alternatively include any other type of drilling tool, such as but not limited to a tap, a die head, etc.

[0045] In the illustrated embodiment, the workpiece 112 is an aircraft component (e.g., an interior panel, an exterior skin panel, etc.). However, the workpiece 112 is not limited to aircraft components. Rather, the drilling system embodiments shown and described herein are applicable to any type of workpiece in which a drilling operation is performed, such as, but not limited to, for example, automotive components, machine components, marine components, aerospace components, panels of larger assemblies, and / or other structures. In addition, as described above, the workpiece surface 110 is not limited to, for example, Figure 1 and Figure 2 The workpiece surface 110 is shown as being approximately flat (eg, having an approximately two-dimensional (2D) shape, etc.) In contrast, in addition to or alternatively to being approximately flat, in other embodiments, one or more sections of the workpiece surface 110 have a three-dimensional (3D) shape (eg, contoured, etc.).

[0046] Reference now Figure 1 and Figure 4 As described above, the pattern generator 104 ( Figure 4 ) is configured to apply a pattern 108 (not shown) on a workpiece surface 110 Figure 1 The pattern generator 104 is configured to be at a reference position relative to the target drilling position 136 (at Figure 1 (not visible in the figure) applies a pattern 108 to a workpiece surface 110, such as Figure 4 As described below, the reference position of pattern 108 corresponds to nose bridge 128 ( Figure 4 The end portion 132 (not shown) Figure 4 ) along the workpiece surface 110, wherein the drilling tool 122 ( Figure 4 ) is aligned with the target drilling location 136.

[0047] The pattern generator 104 is not limited to applying the exemplary pattern 108 shown herein. Rather, the pattern generator 104 is configured to apply the pattern 108 on the workpiece surface 110: (1) at any reference position relative to a target drilling location that enables the drilling system 100 to function as described and / or shown herein (e.g., enables the camera 114 of the drilling end effector 106 to acquire one or more images indicating whether the drilling tool 122 is aligned with the target drilling location, etc.); and (2) having any geometric shape (e.g., size, shape, orientation, etc.) that enables the drilling system 100 to function as described and / or shown herein (e.g., enables the camera 114 of the drilling end effector 106 to acquire one or more images indicating whether the drilling tool 122 is aligned with the target drilling location, etc.). For example, as used herein, the phrase "at a reference position relative to a target drilling location" includes applying the pattern 108 to the workpiece surface 110 at a position: (1) adjacent to the target drilling location; (2) in the vicinity of the target drilling location; (3) a predetermined distance from the target drilling location; (4) at least partially surrounding the target drilling location (e.g., the pattern 108 shown herein, such as Figure 4 (e.g., a pattern 108 that completely surrounds the circumference of the target drilling location 136 on the workpiece surface 110, a pattern 108 that includes one or more segments, each segment surrounding only a portion of the circumference of the target drilling location, etc.); (5) above the target drilling location (e.g., a pattern 108 that covers substantially the entire area of ​​the target drilling location, a pattern 108 that covers only a portion of the target drilling location, etc.); etc. In addition, in addition to or as an alternative to the circular and / or hollow shapes of the exemplary patterns 108 shown herein, the pattern 108 applied to the workpiece surface 110 by the pattern generator 104 may include one or more other shapes, such as, but not limited to, solid shapes, other hollow shapes, polygonal shapes, rectangular shapes, triangular shapes, quadrilateral shapes, other curved shapes, elliptical shapes, hexagonal shapes, octagonal shapes, etc. Optionally, the pattern 108 includes a geometry (e.g., size, shape, orientation, etc.) that is complementary to the geometry of the end portion 132 of the nose bridge 128 (e.g., the size and circular shape of the exemplary pattern 108 shown herein are complementary to the size and circular shape of the exemplary nose bridge 128 shown herein, etc.).

[0048] The pattern generator 104 may include any type of pattern generator configured to apply a pattern 108 formed of one or more of any materials, structures, configurations, etc. that enables the drilling system 100 to function as described and / or shown herein (e.g., enabling the camera 114 of the drilling end effector 106 to acquire one or more images indicating whether the drilling tool 122 is aligned with a target drilling location, etc.). For example, some embodiments of the pattern generator 104 include a printer (e.g., an inkjet printer, a laser printer, a dot matrix printer, a screen printer, a device configured to make a decal, etc.), a painting device (e.g., a spray painting device, a brush painting device, etc.), a writing device (e.g., a pen, a pencil, a marker, etc.), a stamp configured to imprint and thereby deposit material (e.g., ink, paint, etc.) on the workpiece surface 110, a stamp configured to imprint the pattern 108 into the workpiece surface 110, a press configured to squeeze and deposit material (e.g., ink, paint, etc.) onto the workpiece surface 110, a press configured to press the pattern 108 into the workpiece surface 110, an etching device configured to etch the pattern 108 into the workpiece surface 110, etc. Optionally, the pattern generator 104 includes a pattern end effector 144 ( Figure 4 The pattern end effector 144 is configured to be held by the drilling platform 102 (eg, the articulated robotic arm 102a, etc.). Figure 1 102a). Figure 3 A pattern end effector 144 is shown mounted on an articulated robotic arm 102a according to one embodiment.

[0049] Examples of one or more materials, structures, configurations, etc. that create pattern 108 include, but are not limited to, ink, paint, pencil, crayon, chalk, decals, indentations, etching, etc. In some embodiments, pattern 108 may be removed from workpiece surface 110 after the associated drilling operation is completed.

[0050] In some embodiments, the pattern generator 104 simultaneously creates the pattern 108 and applies it to the workpiece surface 110. For example, in some embodiments, the pattern generator 104 includes a printer, a coating device, a writing device, a stamp, and / or a press that creates the pattern 108 by printing, coating, writing, embossing, and / or stamping the pattern 108 directly on (and / or in) the workpiece surface 110, respectively. In other embodiments, the pattern generator 104 first creates the pattern 108 and then applies the pattern 108 to the workpiece surface 110. For example, in some embodiments, the pattern 108 is a decal that is created (e.g., printed, painted, painted, etc.) and then applied to the workpiece surface 110.

[0051] The fabrication of the pattern 108 and the application of the pattern 108 to the workpiece surface 110 can be performed by the same component of the pattern generator 104. For example, an embodiment including a pattern end effector 144 can utilize the pattern end effector 144 to fabricate the pattern 108 and apply it to the workpiece surface 110 (e.g., where the embodiment of the pattern end effector 144 includes a printer, a coating device, a writing device, a stamp, a press, etc.). Another example includes using a component 146 of the pattern generator 104 (e.g., a printer, a coating device, a writing device, a stamp, a press, etc.) that is separate from the drilling platform 102 (i.e., separate from, external to, not configured to be held by the drilling platform 102, etc.) to fabricate the pattern 108 and apply it to the workpiece surface 110. In some embodiments, the component 146 is located within an automated unit (not shown) of the drilling platform 102 that is used to apply the pattern 108 to the surface 110 of the workpiece within the automated unit prior to the drilling operation, while in other embodiments, the component 146 is not located within the automated unit or other location of the drilling platform 102 that is used to apply the pattern 108 to the surface 110 of the workpiece prior to transferring the workpiece 112 to the location of the drilling platform for the associated drilling operation (e.g., located outside the automated unit or other location, remote from the automated unit or other location, etc.).

[0052] In some embodiments, manufacturing the pattern 108 and applying it to the workpiece surface 110 is performed by different components (where the component manufacturing the pattern 108 is optionally a component of the pattern generator 104). For example, embodiments including the pattern end effector 144 can utilize the pattern end effector 144 to apply a pattern 108 (e.g., a decal, etc.) that has been manufactured by another component (such as, but not limited to, another component of the pattern generator 104 (e.g., component 146, etc.), an external device that is not a component of the pattern generator 104, etc.). Another example includes using a first component (e.g., component 146, etc.) of the pattern generator 104 that is separate from the drilling platform 102 (i.e., separate from it, external to it, not configured to be held by it, etc.) to apply a pattern 108 that has been manufactured by another component (such as, but not limited to, another component of the pattern generator 104 (e.g., component 146, etc.), an external device that is not a component of the pattern generator 104, etc.).

[0053] It should be understood from the above examples that in some embodiments, the pattern 108 is produced by the pattern generator, while in other embodiments, the production of the pattern 108 is not performed by the pattern generator 104. For example, in some embodiments, the pattern generator 104 applies a pattern 108 to the workpiece surface 110 that has been previously produced by an external device that is not part of the pattern generator 104.

[0054] The pattern 108 is manufactured and applied to the workpiece surface 110 by: (1) fully automated in certain embodiments; (2) assisted in certain embodiments (e.g., semi-automated, etc.); and (3) fully manual in certain embodiments (e.g., fully performed by an operator, etc.). One example of a fully automated process is a drilling platform 102 that automatically manufactures and applies the pattern 108 to the workpiece surface 110 using a pattern end effector 144. Another example of a fully automated process is a drilling platform that automatically uses a pattern end effector 144 to apply a pattern 108 (e.g., a decal, etc.) that has been automatically manufactured by another component (such as, but not limited to, another component of the pattern generator 104 (e.g., component 146, etc.), an external device that is not a component of the pattern generator 104, etc.). Yet another fully automated example includes using a component 146 of the pattern generator 104 (e.g., a printer, a painting device, a writing device, a stamp, a press, etc.) to automatically manufacture and apply the pattern 108 to the workpiece surface 110. Yet another fully automated example includes using component 146 to automatically apply pattern 108 that is automatically produced by another component (such as, but not limited to, another component of pattern generator 104 , an external device that is not a component of pattern generator 104 , etc.).

[0055] An example of an auxiliary process for making and applying the pattern 108 includes an operator manually applying a pattern 108 (e.g., a decal, etc.) that has been automatically made by another component (such as, but not limited to, another component of the pattern generator 104 (e.g., component 146, etc.), an external device that is not a component of the pattern generator 104, etc.). Another example of an auxiliary process is automatically applying a pattern 108 (e.g., a decal, etc.) that was manually made (e.g., drawn, painted, sprayed, printed, etc.) by an operator using another component (such as, but not limited to, another component of the pattern generator 104 (e.g., component 146, etc.), an external device that is not a component of the pattern generator 104, etc.). It should be understood from the above examples that in some embodiments, the pattern generator 104 includes an operator.

[0056] Examples of a completely manual process for making and applying the pattern 108 include an operator manually making the pattern 108 and applying it to the workpiece surface 110, for example by: (1) painting, varnishing, spraying, stenciling, printing, embossing, stamping, etc., the pattern 108 on the workpiece surface 110; (2) engraving, etching, scraping, embossing, punching the pattern 108 into the workpiece surface 110; (3) by applying (e.g., adhering, etc.) a decal to the workpiece surface 110; and the like.

[0057] In some embodiments including the pattern end effector 144, the drilling end effector 106 and the pattern end effector 144 may be configured to be releasably held by the drilling platform 102 (e.g., by the articulated robotic arm 102a, etc.) such that each of the end effectors 106 and 144 can be selectively secured to and removed from the drilling end effector 106, e.g., to enable the drilling platform 102 to cycle between applying the pattern 108 to the workpiece surface 110 using the pattern end effector 144 and performing a drilling operation on the workpiece surface 110 using the drilling end effector 106. In addition to or as an alternative to being releasably held by the drilling platform 102, some embodiments of the drilling platform 102 include a fixture (not shown) that is capable of simultaneously holding both end effectors 106 and 144 and is configured to move (e.g., rotate, slide, or otherwise move linearly, etc.) to enable the drilling platform to cycle between performing drilling and patterning operations using the drilling end effector 106 and the patterning end effector 144, respectively.

[0058] Reference again Figure 1 and Figure 2 In some embodiments, the drilling system 100 includes one or more cameras 114. In an exemplary embodiment, each camera 114 is mounted to a base 116 of the drilling end effector 106. Each camera 114 is configured to capture a pattern 108 ( Figure 4 and Figure 5 ) of the workpiece surface 110 (eg, Figure 4-6 For example, the camera 114 is configured to allow the end portion 132 of the nosepiece 128 to be positioned at the target drilling position 136 ( Figure 4-6 10 is held on the workpiece surface 110 at a position within the field of view of the camera 114, the camera 114 acquires one or more images of an area (e.g., area 148, etc.) that includes the pattern 108 and the target drilling location 136. As will be described in more detail below, the images acquired by the camera 114 indicate whether the end portion 132 of the nose 128 of the drilling end effector 106 is aligned with the pattern 108 on the workpiece surface 110, so that the drilling tool 122 is aligned with the target drilling location 136.

[0059] Each camera 114 is configured to acquire one or more images of any type, such as, but not limited to, still images, video images, real-time images, delayed images, visible light images, night vision images, and the like. For example, in one exemplary embodiment, one or more cameras 114 are configured to acquire real-time video of an area including both the pattern 108 and the target drilling locations 136. Each camera 114 is any type of camera 114 that enables the camera 114 to function as described and / or illustrated herein (e.g., to acquire multiple images of an area of ​​the workpiece surface 110 including the pattern 108 and the target drilling locations 136, etc.). Examples of cameras 114 include, but are not limited to, still image cameras, video cameras, digital cameras, night vision cameras, visible light cameras, lipstick cameras, and the like. Although in Figure 1 is shown as including a single camera 114 and Figure 2 1 as including two cameras 114 , but in other embodiments, the drilling end effector 106 includes any other number of cameras 114 .

[0060] As described above, in the exemplary embodiment shown herein, each camera 114 is mounted to the base 116 of the drilling end effector 106. In some other embodiments, one or more cameras 114 are additionally or alternatively mounted to the nosepiece 128, the chuck 118, and / or another component of the drilling end effector 106. Furthermore, in some embodiments, one or more cameras 114 are discrete from (i.e., separate from, external to, not mounted to, etc.) the drilling end effector 106 (e.g., one or more cameras 114 are mounted to the drilling platform 102, floor, wall, ceiling, fixture, or other support structure, etc., within the automation platform or at other locations including the drilling platform).

[0061] Each camera 114 is mounted at any position (e.g., location, orientation, alignment, angle, etc.) that enables the camera 114 to function as described and / or illustrated herein (e.g., to acquire an image indicating whether the end portion 132 of the nose 128 of the drilling end effector 106 is aligned with the pattern 108 on the workpiece surface 110, etc.). In the exemplary embodiment illustrated herein, the area 148 ( Figure 4-6) is a plan view (e.g., a bird's-eye view, etc.), but the one or more cameras are not limited to acquiring a plan view. Instead, each camera 114 can acquire images (e.g., to acquire images indicating whether the end portion 132 of the nose 128 of the drilling end effector 106 is aligned with the pattern 108 on the workpiece surface 110, etc.) from any one or more perspectives (e.g., from any one or more angles, etc.) that enable the camera 114 to function as described and / or shown herein. For example, in some embodiments, one or more cameras 114 are configured to acquire an area 148 (at Figure 4-6 ).

[0062] Each camera 114 is mounted using any method, device, structure, mechanism, manner, arrangement, connection, connector, device, etc. that enables the camera 114 to function as described and / or shown herein (e.g., to obtain an image indicating whether the end portion 132 of the nose 128 of the drilling end effector 106 is aligned with the pattern 108 on the workpiece surface 110, etc.). Examples of methods, devices, structures, mechanisms, manners, arrangements, connections, connectors, devices, etc. for mounting one or more cameras 114 in some embodiments include, but are not limited to, adhesives built into the base 116, chuck 118, and / or nose 128; interference fits; snap fits; fasteners (e.g., threaded fasteners, etc.); latches; welding; brazing; epoxy; clips; rings; split pins; quick release pins; clevises; clevis-type connections; bayonet-type connections; spring overrides; etc.

[0063] In some embodiments, one or more parameters of the one or more cameras 114 are selectable, such as to enable calibration of the camera 114. In other words, in some embodiments, one or more parameters of the one or more cameras 114 may be adjusted, changed (e.g., by a user, a technician, etc.), such as to configure the camera 114 to acquire an image of an area (e.g., area 148, etc.) of the workpiece surface 110 that includes both the target drilling location 112 and the pattern 108. Examples of the one or more parameters of the camera 114 that are selected in some embodiments include, but are not limited to, the position of the camera 114 (e.g., position, orientation, alignment, angle, etc.), the speed of the camera 114, the type of image acquired by the camera (e.g., still image, video image, real-time image, delayed image, visible light image, night vision image, etc.), the delay of the image acquired by the camera 114, etc.

[0064] Now only for reference Figure 1In embodiments including one or more cameras 114, each camera 114 is optionally operably connected to one or more optional displays 150 of the drilling system 100 and / or one or more external displays 152 (described below), such that the camera 114 is configured to transmit images acquired thereby to the one or more displays 150 and / or the one or more displays 152 for viewing by an operator of the drilling system 100. For example, in some embodiments, the drilling platform 102, the drilling end effector 106, and / or the control system 142 include one or more displays 150. In an exemplary embodiment, the display 150 is built into an optional user interface 154 of the control system 142. Additionally or alternatively, in some embodiments, the one or more displays 150 are built into the drilling platform 102 and / or the drilling end effector 106. Moreover, in some embodiments, one or more displays 150 are externally attached devices that are mounted to the control system 142, the drilling platform 102, the drilling end effector 106, and / or a support structure (e.g., a fixture, floor, wall, ceiling, table, cart, etc.) of the automation unit or other locations including the drilling platform 102, a control room (not shown), etc. Any display 150 that is an externally attached device is optionally mounted to the control system 142, the drilling platform 102, the drilling end effector 106, and / or the support structure in a configuration such that the position of the display 150 is configured to be adjusted by an operator of the drilling system 100 (e.g., using a telescopic arm; an articulated arm; a flexing arm; a hinge; a fixture capable of tilting, rotating, and / or swiveling, etc.).

[0065] Described above and in Figure 1 The display 150 of the drilling system 100 shown in FIG. 1 is a dedicated display. In other words, the display 150 is dedicated to displaying images acquired by the one or more cameras 114 of the drilling system 100. In addition to or as an alternative to the drilling system 100 including the one or more displays 150, optionally, the one or more cameras 114 of the drilling system 100 are configured to be operably connected to one or more external displays 152 that are not part of the drilling system 100. In other words, in some embodiments, the one or more cameras 114 are configured to be operably connected to one or more external displays 152 that are not dedicated to displaying only images acquired by the one or more cameras 114 of the drilling system 100. Examples of the external display 152 include, but are not limited to, a television, a display panel, a computer monitor, a smart phone, a headset, a virtual reality headset, an augmented reality headset, virtual reality glasses, augmented reality glasses, Google Glass, a handheld screen, a tablet computer, and / or other mobile devices, etc.

[0066] Each display 150 and 152 is operatively connected to the corresponding one or more cameras 114 of the drilling system 100 using any wireless operative connection and / or any wired operative connection that enables (e.g., configured, etc.) the display 150 or 152 to receive and display images acquired by the corresponding one or more cameras 114. Examples of wired operative connections that enable the displays 150 and 152 to receive and display images acquired by the corresponding one or more cameras 114 include, but are not limited to, one or more cables, one or more electrical wires, one or more optical cables, a wired connection to a local area network (LAN), a wired connection to a wide area network (WAN), a wired connection to the Internet, etc. Examples of wireless operative connections that enable the displays 150 and 152 to receive and display images acquired by the corresponding one or more cameras 114 include, but are not limited to, Wi-Fi. TM network, Wireless LAN (WLAN), wireless WAN (WWAN), wireless connection to the Internet, etc.

[0067] Each display 150 and 152 is any type of display that enables the display 150 or 152 to function as described and / or shown herein (e.g., display images acquired by the corresponding camera 114, etc.), such as, but not limited to, a plasma display, a liquid crystal display (LCD), a light emitting diode (LED) display, a cathode ray tube (CRT) display, a projection display, an organic light emitting diode (OLED) display, etc. Although only a single display 150 and a single display 152 are shown, in other embodiments, any other number of displays 150 and any other number of displays 152 may be provided.

[0068] Optionally, the nosepiece 128 includes one or more strain gauges (not shown) configured to measure the load applied to the end portion 132 of the nosepiece 128 by the contact force between the end face 134 of the nosepiece 128 and the workpiece surface 110. Specifically, each strain gauge is configured to measure the load applied to the nosepiece 128 by the contact force between the end face 134 and the workpiece surface 110 at the location of the strain gauge. Therefore, the load measured by each strain gauge indicates the amount of contact force applied by the end face 134 of the nosepiece 128 to the workpiece surface 110 at the location of the strain gauge. Each strain gauge measures the load applied to the nosepiece 128 at the location of the strain gauge in any unit such as, but not limited to, pounds (lbs.), kilograms (kgs.), etc.

[0069] In some embodiments, the one or more cameras 114, the one or more displays 150, and / or the one or more displays 152 are configured such that the one or more displays 150 and / or the one or more displays 152 are configured to display the load measured by the one or more strain gauges. In embodiments where the nosepiece 128 includes more than one strain gauge, the one or more displays 150 and / or the one or more displays 152 may display the load measured by each strain gauge separately and / or may display the average measurement of two or more strain gauges. The nosepiece 128 may include any number of strain gauges. Each strain gauge is mounted to the nosepiece 128 in any position (e.g., location, orientation, alignment, angle, etc.) and using any method, device, structure, mechanism, manner, arrangement, connection, connector, device, etc. that enables the strain gauge to function as described and / or shown herein (e.g., measure a load indicating the amount of contact force applied by the end surface 134 to the workpiece surface 110 at the location of the strain gauge, etc.).

[0070] In operation, the end portion 132 of the nose 128 of the drilling end effector 106 is located on the workpiece surface 110 of the workpiece 112 above the target drilling location 136. In the exemplary embodiment shown herein, the control system 142 automatically commands the articulated robotic arm 102a to automatically position and maintain the end portion 132 of the nose 128 on the workpiece surface 110 above the target drilling location 136. In other embodiments, another type of fully automated drilling system or semi-automated drilling system automatically positions and maintains the end portion 132 of the nose 128 on the workpiece surface 110 above the target drilling location 136. In other embodiments, an operator manually positions the end portion 132 of the nose 128 on the workpiece surface 110 above the target drilling location 136.

[0071] In the exemplary embodiment shown herein, when the end portion 132 of the nosepiece 128 is held on the workpiece surface 110 above the target drilling location 136, the end surface 134 of the nosepiece 128 is engaged into physical contact with the workpiece surface 110 (e.g., as shown in FIG. Figure 1 , etc.), for example, to help orient the drilling tool 122 relative to the workpiece surface 110, to help retain the end portion 132 of the nosepiece 128 on the workpiece surface 100, etc.

[0072] Once the nose 128 has been positioned on the workpiece surface 110 above the target drilling location 136, the one or more images acquired by the one or more cameras 114 are analyzed (e.g., viewed; data, signals, etc. representing the one or more images being accessed) to determine whether the end portion 132 of the nose 128 is aligned (e.g., approximately aligned, precisely aligned, etc.) with the pattern 108 on the workpiece surface 110. In the exemplary embodiment shown herein, the control system 142 automatically analyzes the one or more images acquired by the one or more cameras 114 to determine whether the end portion 132 of the nose 128 is aligned with the pattern 108 on the workpiece surface 110. Additionally or alternatively, the one or more images acquired by the one or more cameras 114 are automatically analyzed by another device (e.g., camera 114, another control system, pattern generator 104, etc.) and / or manually analyzed by an operator viewing the one or more images on one or more optional displays 150 and / or 152. In addition to or in lieu of analyzing the one or more images acquired by the one or more cameras 114, the operator can view the area 148 of the workpiece surface 110 that includes the pattern 108 and the target drilling location 138 via direct line of sight or indirect line of sight (e.g., provided by one or more mirrors, reflectors, etc.) to determine whether the end portion 132 of the nosepiece 128 is aligned with the pattern 108 on the workpiece surface 110. The optional displays 150 and 152 and optional lines of sight also enable the operator to observe the area 148 that includes the pattern 108 and the target drilling location 136 during various positioning, alignment, and drilling operations of the drilling system 100.

[0073] Any relative position (e.g., location, orientation, etc.) between the pattern 108 and the end portion 132 of the nose 128 along the workpiece surface 110 can be used to determine whether the end portion 132 of the nose 128 is aligned with the pattern 108 (whether the relative position is obtained from one or more images acquired by the one or more cameras 114 or obtained by an operator through line of sight). Examples of relative positions between the pattern 108 and the end portion 132 of the nose 128 that can be used to determine whether the end portion 132 is aligned with the pattern 108 include, but are not limited to: whether the pattern 108 is visible when the end portion 132 of the nose 128 is held on the workpiece surface 110 above the target drilling location 136; whether an edge, segment, and / or other geometry of the end portion 132 is aligned with an edge, segment, and / or other geometry of the pattern 108; and the like.

[0074] In the exemplary embodiment shown herein, when the pattern 108 is visible in one or more images acquired by the one or more cameras 114, the end portion 132 of the nose bridge 128 is determined to be misaligned (e.g., not substantially aligned, not precisely aligned, etc.) with the pattern 108. For example, Figure 5An exemplary embodiment of an image 156 of area 148 captured by one or more cameras 114 is shown, the image showing end portion 132 of nose bridge 128 misaligned with a pattern according to one embodiment. Figure 5 As can be seen in FIG. 1 , pattern 108 is visible in image 156 , indicating that end portion 132 of nose bridge 128 is not aligned with pattern 108 .

[0075] In the exemplary embodiment shown herein, the end portion 132 of the nose bridge 128 is determined to be aligned with the pattern 108 when the end portion 132 covers the pattern 108 such that the pattern 108 is not visible in one or more images acquired by the one or more cameras 114. For example, Figure 6 An exemplary embodiment of an image 158 of area 148 captured by one or more cameras 114 is shown, the image showing the end portion 132 of the nose bridge 128 aligned with a pattern according to one embodiment. Figure 6 As can be seen in FIG. 1 , pattern 108 is not visible in image 158 , thereby indicating that end portion 132 of nose bridge 128 is aligned with pattern 108 .

[0076] The determination that the end portion 132 of the nose 128 is aligned with the pattern 108 indicates that the drilling tool 122 is aligned (e.g., approximately aligned, precisely aligned, etc.) with the target drilling location 136. Therefore, upon determining that the end portion 132 of the nose 128 is aligned with the pattern 108 on the workpiece surface 110, the drilling end effector 106 is activated to drill into the workpiece surface 110 at the target drilling location 136.

[0077] The determination that the end portion 132 of the nose 128 is not aligned with the pattern 108 indicates that the drilling tool 122 is not aligned (e.g., not substantially aligned, not precisely aligned, etc.) with the target drilling location 136. Therefore, upon determining that the end portion 132 of the nose 128 is not aligned with the pattern 108, the end portion 132 of the nose 128 is adjustably aligned (e.g., substantially aligned, precisely aligned, etc.) with the pattern 108 on the workpiece surface 110 by moving the drilling end effector relative to the workpiece surface 110 (e.g., along the length and / or width of the workpiece surface 110, etc.). In the exemplary embodiment shown herein, the control system 142 automatically commands the articulated robotic arm 102a to automatically move the drilling end effector 106 relative to the workpiece surface 110, thereby automatically and adjustably aligning the end portion 132 of the nose 128 with the pattern 108 on the workpiece surface 110. In some other embodiments, the end portion 132 of the nosepiece 128 is manually moved by an operator to manually adjustably align the end portion 132 of the nosepiece 128 with the pattern 108 on the workpiece surface 110 .

[0078] The optional displays 150 and 152 and the optional operator's line of sight enable the operator to view the area 148 including the pattern 108 and the target drilling location 136 during various positioning, alignment, and drilling operations of the drilling system 100. In some examples, the area 148 is analyzed during the drilling operation (e.g., drilling into the workpiece surface 110 at the target drilling location 136 using the drilling tool 122, etc.) (e.g., via an operator viewing the area 148 through a line of sight, etc., using one or more images acquired using the one or more cameras 114) to determine and correct any movement of the end portion 132 of the nose 128 out of alignment with the pattern 108, such as caused by "traveling" of the drilling tool 102 along the workpiece surface 110 away from the target drilling location 136, caused by movement of the drilling platform, etc.

[0079] Figure 7 2 is a flow chart illustrating a method 200 for drilling a workpiece according to one embodiment. The method 200 includes applying a pattern on a workpiece surface of a workpiece at a reference position relative to a target drilling position at 202. At 204, the method 200 includes holding a nosepiece of a drilling end effector on the workpiece surface of the workpiece. At 206, the method 200 includes acquiring an image of an area of ​​the workpiece surface including the pattern. The method 200 further includes determining, at 208, using the acquired image, whether an end portion of the nosepiece is aligned with the pattern on the workpiece surface. In some embodiments, determining, at 208, using the acquired image, whether an end portion of the nosepiece is aligned with the pattern on the workpiece surface includes determining, at 208a, whether the pattern is visible in the acquired image.

[0080] The method 200 further includes, at 210, adjustably aligning the end portion of the nose bridge with the pattern on the workpiece surface by moving the drilling end effector relative to the workpiece surface when it is determined that the end portion of the nose bridge is not aligned with the pattern on the workpiece surface. At 212, the method 200 includes drilling a target drilling location with the drilling end effector when it is determined that the end portion of the nose bridge is aligned with the pattern on the workpiece surface.

[0081] Certain embodiments of the present disclosure provide a drilling end effector for drilling a workpiece having a workpiece surface. The drilling end effector includes a chuck configured to hold a drilling tool, and a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion. The nosepiece includes at least one suction cup and at least one suction feed line. The at least one suction cup is fluidically connected to the at least one suction feed line. The at least one suction feed line is configured to be fluidically connected to a suction system. The at least one suction cup is configured to engage in physical contact with the workpiece surface and be pulled under the suction action of the suction system, so that the at least one suction cup adheres to the workpiece surface, thereby maintaining the end portion of the nosepiece on the workpiece surface.

[0082] Certain embodiments of the present disclosure help align a drilling tool with a target drilling location on a workpiece surface. Certain embodiments of the present disclosure help prevent movement (e.g., sliding, slipping, sliding over, etc.) of a drilling tool away from a target drilling location on a workpiece surface, such as before and / or during a drilling operation on the workpiece.

[0083] Certain embodiments of the present disclosure reduce the occurrence of drilling openings at inaccurate locations on the surface of a workpiece (e.g., openings that are not aligned with a target drilling location, etc.). Certain embodiments of the present disclosure reduce damage (e.g., scraping, shaving, scratching, etc.) to a workpiece and / or other structures (e.g., attached substructures, etc.) caused by movement of a drilling tool along the surface of the workpiece. Certain embodiments of the present disclosure reduce the number of broken drilling tools caused by repeated drilling operations. Certain embodiments of the present disclosure help detect, prevent, reduce and / or correct the movement of a drilling tool away from a target drilling location (e.g., sliding, slipping, sliding over, etc.) without increasing the cost and / or complexity of one or more components of the drilling system (e.g., an articulated robotic arm, a drilling end effector, an automated unit that performs drilling operations, a control system, etc.).

[0084] exist Figure 8-14 Another exemplary embodiment of a drilling end effector 306 is shown in FIG. Figure 8 The drilling system 300 includes a drilling platform 302 and a drilling end effector 306. As will be described in more detail below, a nosepiece 328 of the drilling end effector 306 includes a suction fixture 360 ​​configured to hold the nosepiece 328 to a workpiece surface 310 of a workpiece 312.

[0085] Reference now Figure 8 and Fig. 9 , the drilling end effector 306 includes a base 316 and a chuck 318. The base 316 of the drilling end effector 306 is configured to be held by the drilling platform 302. The chuck 318 is held by the base 316 so that the chuck 318 is configured to rotate relative to the base 316 about the rotation axis 320 during operation of the drilling system 300 (e.g., drilling a hole in the workpiece 312, etc.). The drilling end effector 306 includes any suitable drive mechanism (not shown) that is operably connected to the chuck 318 so as to drive the chuck 318 to rotate about the rotation axis 320 (i.e., for applying a torque on the chuck 318 to rotate the chuck 318 about the rotation axis 320), such as but not limited to an electric motor, a manual crank, an internal combustion engine, etc. The chuck 318 is Fig. 9 Not visible in.

[0086] The chuck 318 is configured to hold the drilling tool 322 such that the rotation axis 320 of the chuck 318 is aligned with the centerline axis 324 of the drilling tool 322. The drilling tool 322 is fixed to the chuck 318 such that the drilling tool 322 is configured to rotate with the chuck 318 about the rotation axis 320 and about the centerline axis 324. Specifically, the drilling tool 322 can be rigidly fixed to the chuck 318 such that the chuck 318 transmits torque provided by the drive mechanism to the drilling tool 322, thereby rotating the drilling tool 322 about the rotation axis 320 and the centerline axis 324. In some examples, the chuck 318 is configured to releasably hold the drilling tool 322 such that the drilling tool 322 can be selectively fixed to and removed from the drilling end effector 306, such as for repair or replacement of the drilling tool 322, and / or for maintenance, storage, movement, maintenance of the drilling end effector 106, etc. Drilling tool 322 Fig. 9 Not visible in.

[0087] In the operation of drilling the hole end effector 306 into the workpiece surface 310, the drilling tool 322 rotates about the axes 320 and 324 in a cutting direction (e.g., clockwise, counterclockwise, etc.) that enables the drilling tool 322 to cut into the workpiece surface 310. When the drilling tool 322 rotates about the axes 320 and 324 in the cutting direction, the drilling tool 322 moves toward (e.g., in the direction of arrow 326, etc.) the workpiece surface 310 along the axes 320 and 324 and makes physical contact with the workpiece surface 310. The drilling tool 322 is forced against (e.g., pressed into, etc.) the workpiece surface 310 along the axes 320 and 324 (e.g., in the direction of arrow 326, etc.) to provide a contact force between the drilling tool 322 and the workpiece surface 310. The rotation of the drilling tool 322 in the cutting direction and the contact force between the drilling tool 322 and the workpiece surface 310 cause the drilling tool 322 to cut (e.g., drill, etc.) into the workpiece surface 310.

[0088] The drilling end effector 306 includes a nosepiece 328 mounted to the base 316. The nosepiece 328 extends a length from an end portion 330 to an opposite end portion 332. The end portion 330 of the nosepiece 328 is mounted to the base 316 of the drilling end effector 306 so that when the drilling tool 322 is held by the chuck 318, the nosepiece 328 at least partially surrounds the circumference of the drilling tool 322, e.g., Figure 8 and Fig. 9 As shown. Figure 8 and Fig. 9 As shown, when the nosepiece 328 is mounted to the base 316 of the drilling end effector 306, the length of the nosepiece 328 extends along the axes 320 and 324. Figure 8, the base 316 and the nose piece 328 are cut away so that the interior of the base 316 and the nose piece 328 can be seen to show the chuck 318 and the drilling tool 322.

[0089] The end portion 330 of the nosepiece 328 is rigidly mounted to the base 316 of the nosepiece 328 such that the nosepiece 328 remains stationary relative to the base 316 (i.e., does not rotate with the drilling tool 322 about the axes 320 and 324) during operation of the drilling system 300. In other words, during operation of the drilling system 300, the drilling tool 322 rotates relative to the base 316 and the nosepiece 328 of the drilling end effector 306 about the rotational axis 320 and the centerline axis 324. The end portion 330 of the nose bridge 328 is mounted to the base 316 using any method, device, structure, mechanism, manner, arrangement, connection, connector, device, etc. (such as, but not limited to, adhesive, interference fit, snap fit, fasteners (e.g., threaded fasteners, etc.), latches, welds, brazing, epoxies, clips, rings, cotter pins, quick release pins, clevises, clevis type connections, bayonet connections, spring overrides, etc.) that enables the nose bridge 328 to function as described and / or shown herein.

[0090] The end portion 332 of the nosepiece 328 is configured to be held on the workpiece surface 110 at a position where the centerline axis 324 of the drilling tool 322 is aligned with a target drilling position on the workpiece surface 310. The end portion 332 of the nosepiece 328 includes an end face 334 that is configured to face the workpiece surface 310 of the workpiece 312 when the end portion 332 is held on the workpiece surface 310 (e.g., during drilling of the workpiece 312, etc.). In some embodiments, the end face 334 is configured to engage in physical contact with the workpiece surface 310 of the workpiece 312, for example, to help hold the end portion 332 on the workpiece surface 310.

[0091] The nosepiece 328 includes any structure, configuration, arrangement, geometry, etc. that enables the nosepiece 328 to function as described and / or illustrated herein (e.g., to facilitate alignment of the drilling tool 322 with a target drilling location on the workpiece surface 310, etc.). In the embodiment illustrated herein, the end portion 332 of the nosepiece 328 is defined by a single continuous segment that continuously surrounds (e.g., surrounds approximately an entire circumference, etc.) the drilling tool 322, such as from Fig. 9 and Fig.10 Although shown as including a circle, the end portion 332 of the nose bridge 328 additionally or alternatively includes one or more other shapes, such as, but not limited to, a polygon, a rectangle, a triangle, a quadrilateral, another curved shape, an ellipse, a hexagon, an octagon, etc.

[0092] Any other suitable structure of the end portion 332 that enables the nosepiece 328 to function as described and / or shown herein is considered to be within the scope of the present disclosure. For example, in some other embodiments, the end portion 332 of the nosepiece 328 is defined by any number of discrete segments, each of which extends only around a portion of the circumference of the drilling tool 322 (e.g., any number of discrete legs extending outwardly from the end portion 330, etc.).

[0093] In the exemplary embodiment shown herein, the workpiece surface 310 is substantially flat along the region including the target drilling location. In other embodiments where the region of the workpiece surface 310 including the target drilling location includes a 3D shape (e.g., is contoured, etc.), the end portion 332 (e.g., end face 334, etc.) can include a 3D shape that is complementary to the 3D shape of the region of the workpiece surface 310 including the target drilling location (e.g., as opposed to the approximately flat geometry of the end face 334 of the embodiment shown herein, etc.).

[0094] The nosepiece 328 optionally includes a suction tube 338 configured to collect debris generated during a drilling operation (e.g., during drilling of the workpiece 312, etc.). The suction tube 338 is configured to be in fluid communication with a suction system (not shown) configured to generate suction within the suction tube 338 that enables the suction tube 338 to collect the debris.

[0095] In the embodiments described herein, Figure 8 and Fig. 9 As shown, the drilling platform 302 is an articulated robotic arm 302a, and the articulated robotic arm 302a is configured to, for example, hold a drilling end effector 306 on an end portion 340 of the articulated robotic arm 302a. The articulated robotic arm 302a of the exemplary embodiment provides a fully automated drilling system 300. For example, the articulated robotic arm 302a is configured to automatically move the drilling end effector 306 to a target drilling position on a workpiece surface 310, and activate the drilling end effector 306 to drill into the workpiece 312 using a drilling tool 322. The drilling system 300 includes a control system 342, which is operably connected (e.g., using a wired and / or wireless connection, etc.) to the articulated robotic arm 302a and / or the end effector 306 or incorporated therein as a component of the articulated robotic arm 302a and / or the end effector 306 to control the drilling system 300. For example, the control system 342 is configured to control the movement of the articulated robotic arm 302 a , the initiation of the drilling end effector 306 drilling into the workpiece 312 , other control functions of the drilling system 300 , and the like.

[0096] The drilling platform 302 is not limited to an articulated robotic arm 302a. Rather, additionally or alternatively, the drilling system 300 includes any other type of drilling platform (whether the drilling system 300 is fully automated, semi-automated, or fully manual), such as but not limited to a drill press, a fixture, and / or other structure (e.g., a suspended structure, a structure mounted to the workpiece 312, a structure adjacent to the workpiece 312, a structure resting on and / or attached to the floor, etc.), a gantry drilling platform, a column drilling platform, a handheld drilling platform (e.g., a handheld battery, corded, pneumatic, or hydraulic powered drill, etc.), a less portable drilling device, etc.

[0097] In some embodiments, such as but not limited to, in the exemplary embodiment shown herein, the chuck 318 and the drilling tool 322 held thereby are moved relative to the drilling platform 302 and the base 316 of the drilling end effector 306 to move the drilling tool 322 toward and into physical contact with the workpiece surface 310 along axes 320 and 324 (e.g., in the direction of arrow 326, etc.); and the contact force between the drilling tool 322 and the workpiece surface 310 is provided by a force applied to the chuck 318 and the drilling tool 322 thereby, thereby pressing the drilling tool 322 against the workpiece surface 310.

[0098] The drilling system 300 includes any suitable mechanism, structure, etc., such as, but not limited to, mechanical sleeves, bearings, etc., that enables the chuck 318 and the drilling tool 322 to move relative to the drilling platform 302 and the base 316 of the drilling end effector 306 along the axes 320 and 324. The movement of the chuck 318 and the forces exerted on the chuck 318 and thus on the drilling tool 322 to move the drilling tool 322 relative to the drilling platform 302 and the base 316 toward the workpiece surface 310 and provide a contact force between the drilling tool 322 and the workpiece surface 310 are fully automated in an exemplary embodiment, for example, using electric, hydraulic, and / or pneumatic linear actuators controlled by a control system 342 or the like. In some other embodiments, the movement of the chuck 118 and the force applied to the chuck 118 to move the drilling tool 322 relative to the drilling platform 302 and the base 316 toward the workpiece surface 310 and provide a contact force between the drilling tool 322 and the workpiece surface 310 is: (1) assisted (e.g., semi-automated, etc.), such as using hydraulic cylinders, pneumatic cylinders, gas springs, etc.; or (2) fully manual, such as by an operator applying force directly and / or indirectly on the drilling tool 322 (e.g., using a hand crank, handle, drill press, etc.). In the exemplary embodiment of the drilling end effector 306 shown herein, the nose 328 is rigid along its length so that the drilling tool 322 can be moved toward the workpiece surface 310 along the length of the nose 328 (i.e., relative to the length of the nose 328).

[0099] An example of a fully automated implementation includes the exemplary implementation of an articulated robotic arm 302a shown herein, wherein the drilling platform 302 includes an implementation of a drill press, gantry, or column system that includes a linear actuator (not shown) that automatically moves a drilling tool 322 relative to a base 316 of a drilling end effector 306, for example, upon activation by an operator and / or a control system, and automatically applies a force on the drilling tool 322 that provides a contact force between the drilling tool 322 and a workpiece surface 310. An example of a semi-automated implementation is an implementation in which the drilling platform 302 is a handheld platform that includes a linear actuator and / or other mechanism that is configured to automatically move the drilling tool 322 relative to a base 316 of a drilling end effector 306, for example, upon activation by an operator holding the drilling platform 302, to automatically apply a force on the drilling tool 106 that provides a contact force. An example of a manual system includes an embodiment in which the drilling platform 302 is a drill press including a manual crank that can be manually turned by an operator to indirectly move the drilling tool 322 relative to the base 316 and indirectly exert a force on the drilling tool 322 that provides a contact force between the drilling tool 322 and the workpiece surface 310.

[0100] In some other embodiments, the drilling platform 302 and the base 316 of the drilling end effector 306 are: (1) moved toward the workpiece surface 310 along the axes 320 and 324 (e.g., in the direction of arrow 326, etc.), thereby causing the drilling tool 322 to move toward the workpiece surface 310 and make physical contact therewith; and (2) exerting a force on the base 316 of the drilling end effector 306 to press the drilling tool 322 against the workpiece surface 310, thereby providing a contact force between the drilling tool 322 and the workpiece surface 310. The movement of the base 316 of the drilling end effector 306 and the force applied to the base 116 of the drilling end effector 106 to move the drilling tool 322 toward the workpiece surface 310 and provide a contact force between the drilling tool 322 and the workpiece surface 310 are performed in the following ways: (1) fully automated in some embodiments; (2) assisted in some embodiments (e.g., semi-automated, etc.); and (3) fully manual in some embodiments (e.g., fully performed by an operator, etc.). Examples of fully automated embodiments include an embodiment in which an articulated robotic arm (e.g., articulated robotic arm 302a, etc.) automatically moves the base 316 of the drilling end effector 306, thereby moving the drilling tool 322 toward the workpiece surface 310 and providing a contact force between the drilling tool 322 and the workpiece surface 310. Examples of manual implementations include implementations in which an operator holding the drilling platform 302 manually moves the drilling platform 302, thereby moving the base 316 of the drilling end effector 306, thereby moving the drilling tool 322 toward the workpiece surface 310, and manually applies a force to the drilling platform 302 and the base 316 that provides a contact force between the drilling tool 322 and the workpiece surface 310. In some implementations in which the base 316 of the drilling end effector 306 is moved to move the drilling tool 322 toward the workpiece surface 310 and provide a contact force between the drilling tool 322 and the workpiece surface 310, the nose piece 328 is foldable (e.g., elastically, non-elastically, etc.) along its length to enable the drilling tool 322 to extend beyond the end portion 332 of the nose piece 328 while the nose piece 328 remains on the workpiece surface 310 during the drilling operation.

[0101] In the exemplary embodiment shown herein, the drilling tool 322 is a drill bit, and more specifically a twist drill bit. However, the drilling tool 322 may additionally or alternatively include any type of drill bit, such as but not limited to a step drill bit, a loose drill bit, a hole saw, a center and positioning drill bit, a core drill bit, a countersink drill bit, an ejection drill bit, a gun drill bit, an indexable drill bit, a left-hand drill bit, a metal spade bit, a straight groove drill bit, a drill machine, a lip tooth bone drill bit, a wood spade drill bit, a spoon drill bit, a Forstner drill bit, a center drill bit, a spiral drill bit, a small drill bit, a hinge countersink drill bit, an adjustable wood drill bit, a metal drill bit, a diamond core drill bit, a masonry drill bit, a glass drill bit, a PCB through-hole drill bit, a mounting drill bit, a fishing drill bit, a flexible shaft drill bit, etc. Moreover, the drilling tool 322 is not limited to including a drill bit. Instead, the drilling tool 322 may additionally or alternatively include any other type of drilling tool, such as but not limited to a tap, a die head, etc.

[0102] In the illustrated embodiment, the workpiece 312 is an aircraft component (e.g., an interior panel, an exterior skin panel, etc.). However, the workpiece 312 is not limited to aircraft components. Rather, the drilling system embodiments shown and described herein are applicable to any type of workpiece in which a drilling operation is performed, such as, but not limited to, for example, automotive components, machine components, marine components, aerospace components, panels of larger assemblies, and / or other structures. In addition, as described above, the workpiece surface 310 is not limited to, for example, Figure 1 and Figure 2 The workpiece surface 310 is shown as being approximately flat (e.g., having an approximately two-dimensional (2D) shape, etc.). In contrast, in addition to or alternatively to being approximately flat, in other embodiments, one or more sections of the workpiece surface 310 have a three-dimensional (3D) shape (e.g., contoured, etc.).

[0103] Reference now Figure 8 and Fig.10 , the suction fixture 360 ​​will now be described. The suction fixture 360 ​​includes one or more suction cups 362 and one or more suction feed lines 364. Specifically, the nosepiece 328 of the drilling end effector 306 includes one or more suction cups 362 and one or more suction feed lines 364. In the exemplary embodiment shown herein, the end portion 332 of the nosepiece 328 includes one or more suction cups 362. Each suction cup 362 is fluidly connected to one or more corresponding suction feed lines 364, such as Fig.10 Each suction feed line 364 is fluidically connected to a suction system 366 (at Fig.10 not shown; for example, the suction system 366 of the drilling system 300, an external suction system 366 that is not a component of the drilling system 300, etc.).

[0104] As briefly described above, the suction fixture 360 ​​is configured to hold the nose 328 to the workpiece surface 310. Specifically, in operation, the end portion 332 of the nose 328 is positioned on the workpiece surface 310 of the workpiece 312 above the target drilling location, so that the drilling tool 322 is aligned with the target drilling location on the workpiece surface 310, and one or more suction cups 362 are engaged to be in physical contact with the workpiece surface 310. In the exemplary embodiment shown herein, the control system 342 automatically commands the articulated robotic arm 302a to automatically position the nose 328 on the workpiece surface 310 above the target drilling location 336. In other embodiments, another type of fully automated drilling system or semi-automated drilling system automatically positions the end portion 332 of the nose 328 on the workpiece surface 310 above the target drilling location. In other embodiments, an operator manually positions the end portion 332 of the nose 328 on the workpiece surface 310 above the target drilling location.

[0105] Once the end portion 332 of the nosepiece 328 has been positioned on the workpiece surface 310 above the target drilling location, the suction system 366 is activated to pull the one or more suction cups 362 under suction so that the one or more suction cups 362 adhere to the workpiece surface 310. The adhesion of the one or more suction cups 362 to the workpiece surface 310 holds the end portion 332 of the nosepiece 328 on the workpiece surface 310 (e.g., as shown in FIG. Figure 8 As shown, etc.), so that the drilling tool 322 remains aligned with the target drilling position.

[0106] In the exemplary embodiment shown herein, the control system 342 automatically activates the suction system 366 to pull the one or more suction cups 362 under suction. In other embodiments, another type of fully automated drilling system or semi-automated drilling system automatically activates the suction system 366. In other embodiments, the operator manually activates the suction system 366.

[0107] Optionally, one or more suction cups 362 include strain gauges 368 configured to measure a load representing a contact force (e.g., amount of suction, etc.) applied by the one or more suction cups 362 on the workpiece surface 310. The contact force is between the end surface 134 of the nosepiece 128 and the workpiece surface 110 at the end portion 132 of the nosepiece 128. Each strain gauge 368 measures the contact force applied to the workpiece surface 310 in any unit such as, but not limited to, pounds (lbs.), kilograms (kgs.), etc. In some embodiments, one or more cameras (e.g., Figure 1 and Figure 2 camera 114, etc.) and one or more displays (e.g., Figure 1 The display 150 shown, Figure 1The display 152 shown in the figure, etc.) can be used to display the load measured by one or more strain gauges 368. In embodiments including more than one strain gauge 368, the load measured by each strain gauge 368 can be displayed individually and / or as an average of the measured values ​​of two or more strain gauges 368. Although four are shown, any number of strain gauges 368 can be provided, whether or not the number of strain gauges 368 is the same as the number of suction cups 362.

[0108] Despite Fig.10 362, but the nose 328 may include any other number of suction cups 362. In addition, one or more suction cups 362 may have a structure, arrangement, etc. that enables the suction cup fixture 360 ​​to function as described and / or shown herein (e.g., to hold the end portion 332 of the nose 328 on the workpiece surface 310, so that the drilling tool 322 remains aligned with the target drilling position, etc.). For example, in some embodiments, when the end portion 332 of the nose 328 is held on the workpiece surface 310 by the suction fixture 360, the end surface 334 of the nose 328 is engaged to be in physical contact with the workpiece surface 310, while in other embodiments, when the end portion of the nose 328 is held on the workpiece surface 310 by the suction fixture 360, the end surface 334 of the nose 328 is engaged to be not in physical contact with the workpiece surface 110.

[0109] Reference now Fig.11 ,exist Figure 8 , Fig.10 and Fig.11 In the exemplary embodiment shown, the end surface 334 of the nose piece 328 includes a suction cup 362 that is recessed into the end surface 334 to enable the end surface 334 of the nose piece 328 to be engaged in physical contact with the workpiece surface 310 when the suction cup 362 holds the end portion 332 of the nose piece 328 on the workpiece surface 310. Fig.12 In another example of the configuration, arrangement, etc. of the suction cups 362 shown, the end surface 334 of the nose piece 328 includes one or more suction cups 462 that extend outwardly from the end surface 334 such that the end surface 334 of the nose piece 328 is not engaged into physical contact with the workpiece surface 310 when the suction cups 462 hold the end portion 332 of the nose piece 328 on the workpiece surface 310. Fig.13 In yet another example of the configuration, arrangement, etc. of the suction cups 362 shown in FIG. 1 , the end portion 332 of the nose bridge 328 includes one or more suction cups 562 that are placed side by side with the end surface 334 of the nose bridge 328. Fig.13In the example shown, the suction cup 562 is positioned relative to the end surface 334 of the nose piece 328 such that when the end portion 332 of the nose piece 328 is held on the workpiece surface 310 by the suction cup 562, the end surface 334 is engaged in physical contact with the workpiece surface 310. In some other embodiments, the suction cup 562 is placed side by side with the end surface 334 of the nose piece 328 such that when the end portion 332 of the nose piece 328 is held on the workpiece surface 310 by the suction cup 562, the end surface 334 is not engaged in physical contact with the workpiece surface 310.

[0110] Despite Fig.10 Only a single suction feed line 364 is shown, but the nosepiece 328 may include any other number of suction feed lines 364. In addition, one or more suction feed lines 364 and one or more suction cups 362 may have a structure, arrangement, etc. (e.g., having fluid connectivity, etc.) that enables the suction cup fixture 360 ​​to function as described and / or shown herein (e.g., to hold the end portion 332 of the nosepiece 328 on the workpiece surface 310, so that the drilling tool 322 remains aligned with the target drilling location, etc.). For example, in Fig.10 In the exemplary embodiment shown, the suction cup 362 (e.g., via an exemplary channel 370 in the body 372 of the nosepiece 328, etc.) and the suction feed line 364 are in fluid communication with each other. The fluid communication between the suction cup 362 and the suction feed line 364 can be achieved by connecting the suction feed line 366 to one or more channels 370 (e.g., such as Fig.10 362) and / or provided by direct fluid communication with one or more suction cups 362 via a suction feed line 366. Fig.14 In another example shown, the nosepiece 328 includes two or more suction cups 362, each of which is independently fluidly connected to the suction system 360 ( Figure 8 In some embodiments, the suction feed line 366 is at least partially embedded within the body 372 of the nosepiece 328, e.g., as shown in Fig.10 As shown in the following table.

[0111] Reference now Fig.15 , examples of the present disclosure may be described in the context of using a positioning device to construct one or more portions of an aircraft 700 including a fuselage 702 having a plurality of high-level systems 704 and an interior 706. Examples of high-level systems 704 include one or more of a propulsion system 708, an electrical system 710, a hydraulic fluid system 712, a control system 714, and an environmental system 716. Any number of other systems may be included. Although an aerospace example is shown, the principles may be applied to other industries such as, but not limited to, the automotive industry, the marine industry, and the like.

[0112] You can Fig.16Examples of the present disclosure are described in the context of aircraft manufacturing and service method 800. During pre-production, illustrative method 800 may include an aircraft (e.g., Fig.15 800 and the like) and material procurement 804. During production, component and subassembly manufacturing 806 and system integration 808 of the aircraft are performed. Thereafter, the aircraft may undergo certification and delivery 810 for entry into service 812. During customer entry into service, the aircraft is scheduled for routine maintenance and service 814 (which may also include modification, reconfiguration, refurbishment, etc.).

[0113] Each process of illustrative method 800 may be implemented or performed by a system integrator, a third party, and / or an operator (e.g., a customer, etc.). For purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of marketers, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0114] It should be noted that the systems described herein may include any number of other systems. Additionally, although an aerospace example is shown, the principles may be applied to other industries such as, but not limited to, the automotive industry, the marine industry, and the like.

[0115] The systems and methods shown or described herein may be employed during any one or more stages of the manufacturing and maintenance method 800. For example, components or subassemblies corresponding to component and subassembly manufacturing 806 may be assembled or manufactured in a manner similar to components or subassemblies produced during the aircraft's in-service period. Moreover, one or more aspects of the system, method, or combination thereof may be utilized during the production state of subassembly manufacturing 806 and system integration 808, for example, by substantially speeding up assembly of the aircraft or reducing the cost of the aircraft. Similarly, one or more aspects of the apparatus or method implementation scheme, or combination thereof, may be utilized while the aircraft is in-service (e.g., repair and maintenance 814), for example, but not limited to.

[0116] Various embodiments of the present disclosure help align a drilling tool with a target drilling location on a workpiece surface. Various embodiments of the present disclosure help detect, reduce and / or correct movement (e.g., sliding, slipping, sliding over, etc.) of a drilling tool away from a target drilling location on a workpiece surface, such as before a drilling operation is performed on the workpiece. Various embodiments of the present disclosure help prevent movement (e.g., sliding, slipping, sliding over, etc.) of a drilling tool away from a target drilling location on a workpiece surface, such as before and / or during a drilling operation on the workpiece.

[0117] Various embodiments of the present disclosure reduce the occurrence of drilling openings at inaccurate locations on the surface of a workpiece (e.g., openings that are not aligned with a target drilling location, etc.). Various embodiments of the present disclosure reduce damage (e.g., scraping, shaving, scratching, etc.) to a workpiece and / or other structures (e.g., attached substructures, etc.) caused by movement of a drilling tool along the surface of the workpiece. Various embodiments of the present disclosure reduce the number of broken drilling tools caused by repeated drilling operations. Various embodiments of the present disclosure help detect, prevent, reduce and / or correct the movement of a drilling tool away from a target drilling location (e.g., sliding, slipping, sliding over, etc.) without increasing the cost and / or complexity of one or more components of the drilling system (e.g., an articulated robotic arm, a drilling end effector, an automated unit that performs drilling operations, a control system, etc.). For example, various embodiments of the present disclosure utilize the capabilities of an existing camera on a drilling end effector.

[0118] The following clauses describe other aspects:

[0119] Clause Set A:

[0120] A1. A drilling end effector for drilling a workpiece having a workpiece surface, the drilling end effector comprising:

[0121] a chuck configured to hold a drilling tool; and

[0122] A nose frame configured to at least partially surround the drilling tool when the drilling tool is held by the chuck, the nose frame including an end portion, the nose frame including at least one suction cup and at least one suction feed line, the at least one suction cup being fluidly connected to the at least one suction feed line, the at least one suction feed line being configured to be fluidly connected to a suction system, wherein the at least one suction cup is configured to engage in physical contact with a workpiece surface and be pulled under suction by the suction system so that the at least one suction cup adheres to the workpiece surface, thereby retaining the end portion of the nose frame on the workpiece surface.

[0123] A2. The drilling end effector of clause A1, wherein the end portion of the nosepiece comprises at least one suction cup.

[0124] A3. The drilling end effector according to clause A1, wherein the end portion of the nose bracket includes an end surface configured to face a workpiece surface of the workpiece during drilling of the workpiece, and the end surface of the nose bracket includes at least one suction cup.

[0125] A4. A drilling end effector according to item A1, wherein the end portion of the nose frame includes an end face, which is configured to engage with the workpiece surface of the workpiece in physical contact during drilling of the workpiece, and the end face of the nose frame includes at least one suction cup, wherein at least one suction cup is at least partially recessed in the end face.

[0126] A5. A drilling end effector according to item A1, wherein the end portion of the nose frame includes an end face configured to engage with the workpiece surface in physical contact during drilling of the workpiece, and the end portion of the nose frame includes at least one suction cup so that the at least one suction cup is placed side by side with the end face of the nose frame.

[0127] A6. A drilling end effector according to clause A1, wherein at least one suction feed line is at least partially embedded in the body of the nosepiece.

[0128] A7. A drilling end effector according to item A1, wherein at least one suction cup includes multiple suction cups, and at least one suction feed pipeline includes multiple suction feed pipelines, each suction cup of the multiple suction cups is configured to be independently fluidically connected to the suction system through a corresponding suction feed pipeline of the multiple suction feed pipelines.

[0129] A8. The drilling end effector of clause A1, wherein the at least one suction cup comprises a plurality of suction cups in fluid communication with one another and at least one suction feed line.

[0130] A9. The drilling end effector according to clause A1 further comprises a camera configured to acquire an image of a surface of a workpiece, the image being configured to indicate whether the drilling tool is aligned with a target drilling position.

[0131] A10. The drilling end effector of clause A1, wherein at least one suction cup comprises at least one strain gauge.

[0132] A11. The drilling end effector of clause A1, wherein the drilling end effector is configured to be held by an articulated robotic arm.

[0133] Clause Set B:

[0134] B1. A drilling system for drilling a workpiece having a workpiece surface, the drilling system comprising:

[0135] Drilling platform;

[0136] A drilling end effector configured to be held by a drilling platform, the drilling end effector comprising:

[0137] a chuck configured to hold a drilling tool; and

[0138] A nose frame configured to at least partially surround the drilling tool when the drilling tool is held by the chuck, the nose frame including an end portion, the nose frame including at least one suction cup and at least one suction feed line, the at least one suction cup being fluidly connected to the at least one suction feed line, the at least one suction feed line being configured to be fluidly connected to a suction system, wherein the at least one suction cup is configured to engage in physical contact with a workpiece surface and be pulled under suction by the suction system so that the at least one suction cup adheres to the workpiece surface, thereby retaining the end portion of the nose frame on the workpiece surface.

[0139] B2. A drilling system according to clause B1, wherein the end portion of the nose bridge includes at least one suction cup.

[0140] B3. The drilling system of clause B1, wherein the end portion of the nose bridge comprises an end surface configured to face a workpiece surface of the workpiece during drilling of the workpiece, the end surface of the nose bridge comprising at least one suction cup.

[0141] B4. A drilling system according to item B1, wherein the end portion of the nose bracket includes an end face, which is configured to engage with the workpiece surface of the workpiece in physical contact during drilling of the workpiece, and the end face of the nose bracket includes at least one suction cup, wherein at least one suction cup is at least partially recessed in the end face.

[0142] B5. A drilling system according to clause B1, wherein at least one suction feed line is at least partially embedded in the body of the nosepiece.

[0143] B6. A drilling system according to clause B1, wherein at least one suction cup comprises at least one strain gauge.

[0144] B7. A drilling system according to clause B1, wherein the drilling platform includes an articulated robotic arm.

[0145] Clause Set C:

[0146] C1. A drilling end effector for drilling a workpiece having a workpiece surface, the drilling end effector comprising:

[0147] a chuck configured to hold a drilling tool; and

[0148] A nose frame configured to at least partially surround a drilling tool when the drilling tool is held by a chuck, the nose frame comprising an end portion, the end portion comprising an end face configured to face a workpiece surface during drilling of the workpiece, the nose frame comprising at least one suction feed line, the end face of the end portion of the nose frame comprising at least one suction cup, the at least one suction cup being fluidically connected to the at least one suction feed line, the at least one suction feed line being configured to be fluidically connected to a suction system, the nose frame further comprising a suction tube configured to collect debris during drilling of the workpiece, wherein the at least one suction cup is configured to engage in physical contact with the workpiece surface and be pulled under suction by the suction system so that the at least one suction cup adheres to the workpiece surface, thereby retaining the end portion of the nose frame on the workpiece surface.

[0149] C2. A drilling end effector according to clause C1, wherein at least one suction cup is at least partially recessed in the end surface.

[0150] As used herein, a structure, limitation, or element that is "configured to" perform a task or operation is formed, constructed, or adjusted in a particular structure in a manner corresponding to the task or operation. For the sake of clarity and avoidance of doubt, an object that is merely capable of being modified to perform a task or operation is not "configured to" perform a task or operation as used herein.

[0151] As will be apparent to one skilled in the art, any range or value given herein may be expanded or altered without losing the effect sought.

[0152] Although the subject matter has been described in language specific to structural features and / or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.

[0153] It should be understood that the above benefits and advantages may relate to one embodiment or may relate to several embodiments. The embodiments are not limited to embodiments that solve any or all of the problems described or embodiments that have any or all of the benefits and advantages described. It should be further understood that reference to "an" item refers to one or more of those items.

[0154] In this specification, the term “comprising” means including one or more features or one or more actions followed thereafter, but does not exclude the existence of one or more additional features or actions.

[0155] Unless otherwise noted, the execution order or execution order of the operations in the examples of the present disclosure shown and described herein is not required. That is, unless otherwise noted, the operations can be performed in any order, and the examples of the present disclosure may include more or less operations than the operations disclosed herein. For example, it is expected that it is within the scope of the various aspects of the present disclosure to perform or execute a specific operation before, at the same time, or after another operation (e.g., different steps, etc.).

[0156] When introducing elements of aspects of the present disclosure or examples thereof, the articles "a," "an," "the," and "said" are intended to indicate that there are one or more elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements in addition to the listed elements. The term "exemplary" is intended to mean "an example of..." The phrase "one or more of A, B, and C below" means "at least one of A and / or at least one of B and / or at least one of C."

[0157] Having described various aspects of the disclosure in detail, it will be apparent that modifications and variations may be made without departing from the scope of various aspects of the disclosure as defined in the appended claims. As various changes may be made to the above constructions, products and methods without departing from the scope of various aspects of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense.

[0158] It should be understood that the above description is intended to be illustrative rather than restrictive. For example, the above embodiments (and / or aspects thereof) can be used in combination with each other. In addition, without departing from the scope of the present disclosure, many modifications can be made to adapt specific situations or materials to the teachings of the various embodiments of the present disclosure. Although the size and type of materials described herein are intended to limit the parameters of the various embodiments of the present disclosure, the embodiments are by no means meant to be restrictive and are only exemplary embodiments. After reading the above description, many other embodiments will be apparent to those of ordinary skill in the art. Therefore, the scope of the various embodiments of the present disclosure should be determined with reference to the appended claims and the full scope of the equivalents granted by these claims. In the appended claims, the terms "including" and "wherein" are used as the ordinary English equivalents of the corresponding terms "including" and "wherein". In addition, the terms "first", "second" and "third", etc. are used only as marks and are not intended to impose numerical requirements on their objects. In addition, the limitations of the appended claims are not written in a device-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112 (f), unless and until such claim limitations explicitly use the phrase "device for...", followed by a functional statement without further structure.

[0159] This written description uses examples to disclose various embodiments of the present disclosure, including the best mode, and also enables a person of ordinary skill in the art to implement the various embodiments of the present disclosure, including making and using any device or system and performing any combined method. The scope of patent protection for the various embodiments of the present disclosure is defined by the claims, and may include other examples that occur to a person of ordinary skill in the art. If these other examples have structural elements that are not different from the literal language of the claims, or if the examples include equivalent structural elements that are not substantially different from the literal language of the claims, these other examples are intended to be within the scope of the claims.

Claims

1. A drilling end effector for drilling a workpiece having a workpiece surface, the drilling end effector comprising: a chuck configured to hold a drilling tool; as well as a nose frame configured to at least partially surround the drilling tool when the drilling tool is held by the chuck, the nose frame comprising an end portion, the nose frame comprising at least one suction cup and at least one suction feed line, the at least one suction cup being fluidically connected to the at least one suction feed line, the at least one suction feed line being configured to be fluidically connected to a suction system, wherein the at least one suction cup is configured to engage in physical contact with the workpiece surface and be pulled under suction by the suction system so that the at least one suction cup adheres to the workpiece surface to thereby hold the end portion of the nose frame on the workpiece surface, wherein the end portion of the nose frame comprises an end face configured to engage in physical contact with the workpiece surface of the workpiece during drilling of the workpiece, the end face of the nose frame comprising the at least one suction cup, wherein the at least one suction cup is at least partially recessed into the end face.

2. The drilling end effector of claim 1, wherein the at least one suction cup further comprises at least one suction cup placed side by side with the end surface of the nose bridge.

3. The drilling end effector according to any one of claims 1 to 2, wherein the at least one suction feed line is at least partially embedded in the body of the nosepiece.

4. The drilling end effector according to any one of claims 1 to 2, wherein the at least one suction cup comprises a plurality of suction cups and the at least one suction feed pipeline comprises a plurality of suction feed pipelines, each of the plurality of suction cups being configured to be independently fluidically connected to the suction system through a corresponding one of the plurality of suction feed pipelines.

5. The drilling end effector according to any one of claims 1 to 2, wherein the at least one suction cup comprises a plurality of suction cups in fluid communication with each other and the at least one suction feed line.

6. The drilling end effector according to any one of claims 1 to 2, further comprising a camera, wherein the camera is configured to acquire an image of the workpiece surface, wherein the image is configured to indicate whether the drilling tool is aligned with a target drilling position.

7. The drilling end effector according to any one of claims 1 to 2, wherein the at least one suction cup comprises at least one strain gauge.

8. The drilling end effector according to any one of claims 1 to 2, wherein the drilling end effector is configured to be held by an articulated robotic arm.

9. The drilling end effector according to any one of claims 1 to 2, wherein the nose frame further comprises a suction tube configured to collect debris during drilling of the workpiece, wherein the at least one suction cup is configured to engage in physical contact with the workpiece surface and be pulled under the suction action of the suction system so that the at least one suction cup adheres to the workpiece surface, thereby retaining the end portion of the nose frame on the workpiece surface.

10. A drilling system for drilling a workpiece having a workpiece surface, the drilling system comprising the drilling end effector according to claim 1, wherein the drilling system comprises: A drilling platform, wherein the drilling end effector is configured to be held by the drilling platform and on the drilling platform.

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