Indexing apparatus and indexing method

Abstract

The present application relates to an indexing apparatus and an indexing method. The indexing apparatus includes a stationary tool movable relative to an operating unit and an indexing feature fixed relative to the stationary tool. The indexing apparatus also includes a gripper configured to engage the indexing feature. The indexing apparatus also includes a controller in communication with the gripper. The controller is configured to position the stationary tool relative to the operating unit based on a gripper position of the gripper engaged with the indexing feature.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to manufacturing, and more particularly, to an indexing apparatus and indexing method during manufacturing operations. BACKGROUND

[0002] Many structures, parts, and components are manufactured using large automated machines that have a fixed base and operate under computer control along predetermined tool paths. This manufacturing technique requires that the workpiece be accurately indexed relative to the machine. One method of indexing the workpiece is to probe the workpiece at different locations to align or "zero" the machine's tooling with the workpiece's instant position based on the probed locations. Another method of indexing the workpiece is to use a fixture to secure the workpiece in a specific repeatable position. However, both of these methods are time consuming and expensive processes that require significant setup each time the workpiece is moved to a new work position or a new workpiece is moved to the work position. This problem is exacerbated for large structures such as aircraft spars, wing sections, fuselage sections, etc. that can require a very large number of probe locations or a very large fixture. Furthermore, neither of these methods is conducive to continuous manufacturing where the workpiece needs to be moved quickly and accurately from one work position to another. Therefore, those skilled in the art continue with their work in the field of indexing during manufacturing, and as a result, devices and methods that aim to solve the aforementioned problems have utility.

[0003] The abstract of EP 3733387 A1 recites, "A reinforced composite layup placement system (1100) is presented. The reinforced composite layup placement system includes: a longitudinal end effector (1104) having a first attachment point and a second attachment point; a first rotary arm (1108) having a first connector configured to connect to the first attachment point; a first movement system configured to move the first rotary arm within a manufacturing environment; a second rotary arm (1110) having a second connector configured to connect to the second attachment point; and a second movement system configured to move the second rotary arm within the manufacturing environment."

[0004] The abstract of EP 2923794 A1 recites, "A system for assembly manufacturing can include at least one pinning unit (20) configured to perform at least one pinning fastening operation on a workpiece; at least one fastening unit (22) configured to perform at least one final fastening operation on the workpiece; and a material handling system (26) linking the pinning unit (20) and the fastening unit (22), wherein the material handling system (26) positions the workpiece within the pinning unit (20), and wherein the material handling system (26) transfers the workpiece from the pinning unit (20) to the fastening unit (22)."

[0005] The abstract of EP 318699 A1 recites, "Systems (100) and methods (1100) for proximity detection in a manufacturing environment are provided. One embodiment is a method (1100) for reporting proximity in an assembly environment (130). The method (1100) includes inserting (1102) an arm (1026) of a holder (1020) into an interior (1004) of a part (1000) held by a carrier (1010) and worked on by a robot (140, 1030, 1250), placing (1104) an indexing feature (1016) at the holder (1020) into contact with an indexing feature (1023) of the carrier (1010), operating (1106) a sensor (120, 1028, 1270) at the holder (1020) to directly detect a position of a first proximity detector (160, 300, 410, 1260) worn by a technician (150, 920) and a position of a second proximity detector (162, 300, 420, 430, 1290) at the robot (140, 1030, 1250), and guiding (1108) the first proximity detector (160, 300, 410, 1260) to provide a warning to the technician (150, 920) if a distance between the first proximity detector (160, 300, 410, 1260) and the second proximity detector (162, 300, 420, 430, 1290) is less than a threshold value".

[0006] The abstract of EP 0807504 A1 recites, "A method of manufacturing a laid-up, bonded and cured composite part includes filling recesses (64) in a face of a tool (32) with a foaming, self-skinning sacrificial material and covering the face of the tool with a caul plate. The tool is heated to cure the foaming material, fill the recesses and form a hard, smooth surface skin on the foam that is flush with the face of the tool. A series of plies (85) are laid up on the face of the tool to form a tool-side skin, and other components (84) of the part are laid up on top of the tool-side skin plies. A binder / resin matrix is applied to or pre-impregnated into the skin plies and components for bonding / curing to form a rigid monolithic assembly of the skin and components. A vacuum bag (71) is applied over the laid-up skin and components. The binder / resin matrix is bonded / cured to transform the skin and components into the rigid monolithic assembly. The tool is fixed in a known position on a CNC machine tool to position the face of the tool in a known position for edge routing of the rigid monolithic assembly by the machine tool. A cutter (68) of the machine tool is guided in a predetermined path around the face of the tool, with the cutter extending into the recesses below the face of the tool and cutting a perimeter edge around the rigid monolithic assembly. After edge routing, the rigid monolithic assembly is a finished part and is removed from the face of the tool." SUMMARY

[0007] The following is a non-exhaustive list of examples in accordance with the subject matter of the present disclosure, which can or can not be claimed.

[0008] In one example, a disclosed indexing apparatus includes a fixed tool movable relative to an operating cell and an indexing feature fixed relative to the fixed tool. The indexing apparatus also includes a gripper configured to engage the indexing feature. The indexing apparatus further includes a controller in communication with the gripper. The controller is configured to position the fixed tool relative to the operating cell based on a gripper position of the gripper engaged with the indexing feature.

[0009] In one example, a disclosed manufacturing system includes an automated machine located in an operating cell and configured to perform at least one manufacturing operation. The manufacturing system also includes a fixed tool configured to support a workpiece and movable relative to the operating cell and an indexing feature fixed relative to the fixed tool. The manufacturing system further includes a gripper configured to engage the indexing feature. The manufacturing system also includes a controller in communication with the gripper and the automated machine. The controller is configured to position the fixed tool relative to the operating cell based on a gripper position of the gripper engaged with the indexing feature. The controller is also configured to index the automated machine relative to a fixed tool position of the fixed tool.

[0010] In one example, a disclosed manufacturing method includes the steps of: (1) moving a fixed tool relative to an operating cell; (2) engaging an indexing feature with a gripper; (3) positioning the fixed tool relative to the operating cell based on a gripper position of the gripper engaged with the indexing feature; and (4) indexing an automated machine relative to a fixed tool position of the fixed tool.

[0011] Other examples of the disclosed apparatus, systems, and methods will become apparent from the following detailed description, drawings, and appended claims. BRIEF DESCRIPTION OF DRAWINGS

[0012] FIG. 1 is an example of an indexing apparatus;

[0013] FIG. 2 is an example of a manufacturing system using the indexing apparatus;

[0014] FIG. 3 is an example of an interface device, an indexing feature, and a fixed tool of the indexing apparatus;

[0015] FIG. 4 is an example of the indexing apparatus;

[0016] FIG. 5 is a schematic top plan view of an example of an indexing apparatus;

[0017] FIG. 6 is a schematic top plan view of an example of an indexing apparatus;

[0018] FIG. 7 is a schematic block diagram of an example of a processing operation for determining a position of a fixture of an indexing apparatus;

[0019] FIG. 8A is a schematic perspective view of an example of a gripper of an interface arrangement of an indexing apparatus;

[0020] FIG. 8B is a schematic perspective view of an example of an indexing feature of an indexing apparatus;

[0021] FIG. 9A is a schematic perspective view of an example of a gripper of an interface arrangement of an indexing apparatus;

[0022] FIG. 9B is a schematic perspective view of an example of an indexing feature of an indexing apparatus;

[0023] FIG. 10 is a schematic perspective plan view of an example of a manufacturing system;

[0024] FIG. 11 is a schematic perspective view of an example of a manufacturing system using an indexing apparatus;

[0025] FIG. 12 is a schematic top plan view of an example of an indexing apparatus;

[0026] FIG. 13 is a schematic perspective view of an example of an interface arrangement, an indexing feature and a fixture of an indexing apparatus;

[0027] FIG. 14 is a schematic top plan view of an example of an indexing apparatus;

[0028] FIG. 15 is a schematic top plan view of an example of an indexing apparatus;

[0029] FIG. 16 is a schematic block diagram of an example of a processing operation for determining a position of a fixture of an indexing apparatus;

[0030] FIG. 17 is a schematic perspective view of an example of an indexing feature and a fixture of an indexing apparatus;

[0031] FIG. 18 is a schematic perspective view of an example of an indexing feature and a fixture of an indexing apparatus;

[0032] FIG. 19 is a schematic perspective view of an indexing feature of an indexing apparatus and a fixture that is an example;

[0033] FIG. 20 is a schematic perspective plan view of a manufacturing system that is an example;

[0034] FIG. 21 is a schematic perspective view of a manufacturing system using an indexing apparatus that is an example;

[0035] FIG. 22 is a schematic plan view of an indexing apparatus that is an example;

[0036] FIG. 23 is a schematic perspective view of an interface device, an indexing feature, and a fixture of an indexing apparatus that is an example;

[0037] FIG. 24 is a schematic block diagram of a processing operation for determining a position of a fixture of an indexing apparatus that is an example;

[0038] FIG. 25 is a schematic front view of an indexing feature of an indexing apparatus and a fixture that is an example;

[0039] FIG. 26 is a schematic front view of an indexing feature of an indexing apparatus and a fixture that is an example;

[0040] FIG. 27 is a schematic front view of a probe of an interface device, an indexing feature, and a fixture of an indexing apparatus that is an example;

[0041] FIG. 28 is a schematic perspective plan view of a manufacturing system that is an example;

[0042] FIG. 29 is a flowchart of a manufacturing method that is an example;

[0043] FIG. 30 is a flowchart of a manufacturing method that is an example;

[0044] FIG. 31 is a flowchart of a manufacturing method that is an example;

[0045] FIG. 32 is a schematic block diagram of a controller of an indexing apparatus that is an example;

[0046] FIG. 33 is a flowchart of an aircraft manufacturing and servicing method; and

[0047] FIG. 34 is a block diagram of an aircraft. DETAILED DESCRIPTION

[0048] The following detailed description references the drawings, wherein like numerals indicate the same features throughout the several figures. Other embodiments and examples of the disclosure are described below.

[0049] The following provides illustrative, non-exhaustive examples of subject matter that can but need not be claimed as examples in accordance with the disclosure. References herein to “an example” mean that a particular feature, structure, element, component, characteristic, and / or operation described in connection with the example is included in at least one implementation and / or implementation of the subject matter described herein. Thus, appearances of the phrase “an example,” “another example,” “one example,” and similar language in the specification, throughout this disclosure, and in the claims are not necessarily all referring to the same example. Furthermore, the subject matter including any features, structures, elements, components, characteristics, and / or operations described in connection with any one example can but need not comprise, and should not necessarily be construed as comprising, any of the subject matter including any features, structures, elements, components, characteristics, and / or operations described in connection with any other example. Moreover, the subject matter including any features, structures, elements, components, characteristics, and / or operations described in connection with any one example can but need not comprise, and should not necessarily be construed as comprising, any of the subject matter including any features, structures, elements, components, characteristics, and / or operations described in connection with any other example.

[0050] Reference is made generally to FIGS. 1-33 As examples, the disclosure describes a repositioning apparatus 100 for positioning a workpiece 170 and repositioning the workpiece during a manufacturing operation, a manufacturing system 168 utilizing the repositioning apparatus 100, and manufacturing methods 1000, 2000, 3000 utilizing the repositioning apparatus 100 to position a workpiece 170 and reposition the workpiece.

[0051] FIG. 1 An example of a repositioning apparatus 100 is shown schematically. Generally, the repositioning apparatus 100 provides a means for precisely and repeatably determining a position of a workpiece 170 relative to a frame of reference 216 defined by a fixed coordinate system 112. FIG. 1 An example of a manufacturing system 168 including the repositioning apparatus 100 is also shown schematically. The manufacturing system 168 includes or forms at least a portion of an operating cell 106. An automated machine 128 is located within the operating cell 106 and is configured to perform at least one manufacturing operation on the workpiece 170. The operating cell 106 is defined or described by the fixed coordinate system 112 and includes a work envelope 140. The work envelope 140 forms a three-dimensional volume within the operating cell 106 described by the fixed coordinate system 112 in which the automated machine 128 operates.

[0052] Reference is made to FIG. 1The transfer device 100 includes a fixture 102. The fixture 102 is configured to securely hold the workpiece 170. The fixture 102 includes various suitable holding features 260 that enable the workpiece 170 to be secured to or otherwise held to the fixture 102. The fixture 102 is movable relative to the operating cell 106, e.g., relative to the automated machine 128 located within the operating cell 106. For example, the fixture 102, along with the workpiece 170 secured to the fixture 102, is moved into a work location 258 within the work envelope 140 of the operating cell 106.

[0053] As used herein, the term "work location 258" generally refers to the spatial situation of the fixture 102, and thus the workpiece 170, when the fixture 102 is moved within the operating cell 106 in order to perform at least one manufacturing operation on the workpiece 170 by the automated machine 128. The present disclosure recognizes and accounts for the fact that the work location 258 can not be precisely known when the fixture 102 is moved within the operating cell 106. Accordingly, the transfer device 100 is configured to determine the position of the fixture 102 relative to the reference frame 216 (also referred to herein as the fixture position 118), and thus the position of the workpiece 170 relative to the reference frame 216 (also referred to herein as the workpiece position 262), when the fixture 102 is at the work location 258.

[0054] The transfer device 100 includes a transfer feature 104. The transfer feature 104 is fixed relative to the fixture 102. In other words, the position of the transfer feature 104 relative to the fixture 102 is constant, independent of the position (or change in position) of the fixture 102 relative to the reference frame 216. In one example, the transfer feature 104 is coupled to the fixture 102. In another example, the transfer feature 104 is located on the fixture 102. In yet another example, the transfer feature 104 forms a part of (e.g., is integral with) the fixture 102.

[0055] Throughout the present disclosure, the term "position" refers to the linear situation of an object along one or more orthogonal axes in a three-dimensional space, e.g., along the fixed coordinate system 112. Additionally, in some cases, the term "position" also refers to the angular situation (e.g., orientation) of an object with respect to one or more orthogonal axes in a three-dimensional space, e.g., with respect to the fixed coordinate system 112. Generally, the "position" of an object refers to the X-position of at least a portion of one or more external surfaces of the object (e.g., the X-coordinates of a plurality of points representing at least a portion of the external surface), the Y-position of at least a portion of one or more external surfaces of the object (e.g., the Y-coordinates of a plurality of points representing at least a portion of the external surface), and the Z-position of at least a portion of one or more external surfaces of the object (e.g., the Z-coordinates of a plurality of points representing at least a portion of the external surface).

[0056] Still referring to FIG. 1 The indexing apparatus 100 includes an interface device 220. The interface device 220 is configured to interface with the indexing feature 104 and position the indexing feature 104 relative to the reference frame 216, for example, within the operating cell 106. The interface device 220 is configured to generate interface data 222 that represents a position of the indexing feature 104 relative to the reference frame 216 (also referred to herein as an indexing feature position 116). As will be described in greater detail herein, the interface device 220 can use at least one of the gripper 108, the sensor 184, and a plurality of probes 202 to interface with and position the indexing feature 104.

[0057] The indexing apparatus 100 also includes a controller 110. The controller 110 is in communication (e.g., electrical and / or data communication) with the interface device 220. The controller 110 is configured to process the interface data 222 generated by the interface device 220 and determine the indexing feature position 116 based on the interface data 222. The controller 110 is also configured to determine a current (e.g., real-time, actual) position of the fixture tool 102, and thus the workpiece 170, relative to the reference frame 216 based on the indexing feature position 116. The automated machine 128 is indexed relative to the fixture tool 102 based on the determined position of the fixture tool 102 (fixture tool position 118).

[0058] In the disclosed examples, the geometry of the workpiece 170, the geometry of the fixture tool 102, and the geometry of the indexing feature 104 are known. As used herein, the “geometry” of an object refers to the size, shape, and form of the object and any surface contours of the object. The geometry of an object can include the internal geometry of the object and / or the external geometry of the object. For example, the geometry of the workpiece 170 describes the size, shape, and form of the workpiece 170 and any surface contours of the workpiece 170.

[0059] Additionally, the workpiece 170 is fixed or otherwise secured to the fixture tool 102 at a known position relative to the fixture tool 102. In other words, the position of the workpiece 170 relative to the fixture tool 102 (workpiece position 262) is known and remains constant regardless of the position (or change in position) of the fixture tool 102 relative to the reference frame 216, for example, when the fixture tool 102 is moved into or out of the operating cell 106. Similarly, the position of the workpiece 170 is also fixed and remains constant relative to the indexing feature 104.

[0060] Accordingly, the index feature location 116 can be used to determine the fixture tool location 118. In turn, the fixture tool location 118 can be used to assume that the workpiece location 262 is within tolerance. In other words, the fixture tool location 118 represents the instantaneous location of the fixture tool 102 and the workpiece 170 relative to the reference frame 216. As such, throughout this disclosure, unless otherwise noted, the term "fixture tool location 118" represents and incorporates the location of the workpiece 170 (workpiece location 262).

[0061] In one example, prior to the beginning of the positioning and indexing operations, the controller 110 is configured to identify the fixture tool 102, the index feature 104, and the workpiece 170 on which manufacturing operations will be performed. In one example, the type of fixture tool, the type of index feature, and / or the type of workpiece can be loaded into the program prior to executing the positioning and indexing instructions. In another example, the program can actively identify and select the type of fixture tool, the type of index feature, and / or the type of workpiece from a database of options based on one or more predetermined selection criteria.

[0062] Accordingly, based on the type of fixture tool 102, the type of index feature 104, and / or the type of workpiece 170 identified by the controller 110, the geometry of the fixture tool 102, the geometry of the index feature 104, and the geometry of the workpiece 170 are known. For example, the program loads a digital model 120 representing the fixture tool 102, the index feature 104, and the workpiece 170. The geometry of the fixture tool 102 (also referred to herein as fixture tool geometry 264), the geometry of the index feature 104 (also referred to herein as index feature geometry 266), and the geometry of the workpiece 170 (also referred to herein as workpiece geometry 268) are represented by or extracted from the digital model 120. FIG. 1 ) represents or extracts from the digital model 120.

[0063] In one example, the digital model 120 includes a digital representation of the fixture tool 102, the index feature 104, and the workpiece 170. In another example, the digital model 120 includes a digital representation of the combination of the fixture tool 102 with the index feature 104 and the workpiece 170 secured to the fixture tool 102. Accordingly, the digital model 120 represents the location of the index feature 104 and / or the workpiece 170 relative to the fixture tool 102.

[0064] Still referring to FIG. 1During the positioning and indexing operations, the controller 110 is configured to match the indexing feature geometry 266 to the indexing feature location 116 represented by the interface data 222. For example, the controller 110 registers the geometric representation of the indexing feature 104 of the digital model 120 to the indexing feature location 116. The controller 110 then determines a position of the digital model 120 relative to the reference frame 216 (referred to herein as the model position 126) to thereby position the digital model 120 in the reference frame 216. The registration of the digital model 120 to the indexing feature location 116 can be performed using any of a variety of data computation techniques that best align a set of data points (e.g., representing the digital model 120) to a set of reference data points (e.g., representing the indexing feature location 116), such as point cloud transformation. The controller 110 then determines a position of the fixed tool 102 and a position of the workpiece 170 (the fixed tool position 118) relative to the reference frame 216 based on the model position 126. For example, the fixed tool position 118 is assumed to be the model position 126 within a tolerance.

[0065] The automated machine 128 is then indexed relative to the fixed tool 102 based on the fixed tool position 118 relative to the reference frame 216. The automated machine 128 operates along a well-defined, programmed (e.g., numerically controlled) motion cycle or tool path in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216.

[0066] In one example, the automated machine 128 includes a robotic arm 226 having a plurality of degrees of freedom, and an end effector 228 coupled to a working end of the robotic arm 226. The end effector 228 includes or takes the form of at least one work tool configured to perform at least one manufacturing operation on the workpiece 170. The robotic arm 226 is configured to move the end effector 228 along a predetermined tool path relative to the fixed tool 102 and the workpiece 170 based on the fixed tool position 118 under computer control.

[0067] Generally, the positioning and indexing operations described herein can be performed in conjunction with or as an initial step associated with any of a variety of types of additive or subtractive manufacturing operations. As such, the automated machine 128 can perform any of a variety of types of manufacturing operations on the workpiece 170, including but not limited to drilling operations, milling operations, fastening operations, pre- and / or post-cure composite assembly operations (e.g., material layup operations, lamination operations, etc.), etc. Generally, the end effector 228 includes an appropriate tool configured to perform the associated manufacturing operation.

[0068] Because the geometry of the workpiece 170 is known, and because the position of the workpiece 170 relative to the fixture tool 102 is known, or assumed to be within tolerance, the automated machine 128 is indexed relative to the fixture tool position 118, and thus relative to the workpiece 170, based on the position of the fixture tool 102. Once the automated machine 128 is indexed relative to the fixture tool position 118, the automated machine 128 operates along the programmed tool path to perform at least one manufacturing operation on the workpiece 170 in a known manner. The known geometry of the workpiece 170 and the known position of the workpiece 170 relative to the fixture tool 102 are incorporated into and accounted for by the programmed tool path of the automated machine 128.

[0069] The present disclosure recognizes and appreciates that the geometry of the workpiece 170 can change as a result of manufacturing (e.g., assembly or machining) operations performed on the workpiece 170. However, the position of the workpiece 170 relative to the fixture tool 102 and the indexing feature 104 does not change as a result of actions other than manufacturing operations. Thus, any bending, shifting, etc. of the workpiece 170 is within tolerance during manufacturing operations, and has no effect on the position of the workpiece 170 beyond tolerance. In other words, at each stop along the complete manufacturing process, the only change to the workpiece 170 is the geometry as a result of various manufacturing operations.

[0070] The change to the geometry of the workpiece 170 as a result of any manufacturing operation is also known, or assumed to be within tolerance, based on the theoretical additions or subtractions from previous manufacturing operations. For example, the workpiece geometry 268 (e.g., represented by the digital model 120) is updated based on the additive or subtractive manufacturing operations performed on the workpiece 170.

[0071] When the fixture tool 102 and the workpiece 170 are moved to a subsequent work position 258, such as to the second operation cell 172 to perform a subsequent manufacturing operation on the workpiece 170 by the second automated machine 174 FIG. 10 、 FIG. 20 and FIG. 28 the indexing feature 104 is positioned relative to the fixture tool position 118, the fixture tool position 118 is determined, the second automated machine 174 is indexed, as described herein. The known (e.g., changed) geometry of the workpiece 170 and the known position of the workpiece 170 relative to the fixture tool 102 are incorporated into and accounted for by the programmed tool path of the second automated machine 174. Thus, this change in the workpiece geometry 268 is accounted for in the subsequent positioning and indexing operations, which in turn enables repeatable indexing based on the position of the fixture tool 102.

[0072] Accordingly, the examples of the indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 disclosed herein enable rapid and accurate positioning of the workpiece 170 without the need for expensive and time-consuming setup operations or positioning operations. The automated machine 128 can again be rapidly and precisely indexed based on the determined position of the fixture tool 102 relative to the fixture tool 102 and thus the workpiece 170.

[0073] FIGS. 1-29 Various example implementations of the interface arrangement 220 and indexing feature 104 of the disclosed indexing apparatus 100 are schematically illustrated. As FIGS. 1-10 shown, in one example, the interface arrangement 220 includes at least one gripper 108 that provides a contact interface with the indexing feature 104. As FIGS. 11-21 shown, in one example, the interface arrangement 220 includes at least one sensor 184 that provides a non-contact interface with the indexing feature 104. As FIGS. 22-29 shown, in one example, the interface arrangement 220 includes a plurality of probes 202 that provide a contact interface with the indexing feature 104.

[0074] Referring generally to FIG. 1 , and specifically to FIGS. 2-4 , in one example, the indexing apparatus 100 includes a fixture tool 102. The fixture tool 102 is movable relative to the operating unit 106. The indexing apparatus 100 further includes an indexing feature 104. The indexing feature 104 is fixed relative to the fixture tool 102. For example, the indexing feature 104 is coupled to the fixture tool 102. In one example, the indexing feature 104 extends from the fixture tool 102.

[0075] In the example shown in FIGS. 2-5 , the indexing feature 104 is coupled to and extends from a front end of the fixture tool 102. In other examples, the indexing feature 104 is coupled to or located on another portion (e.g., side, rear, bottom, etc.) of the fixture tool 102.

[0076] In one example, the indexing apparatus 100 includes a gripper 108. The gripper 108 is movable relative to the operating unit 106 and the fixture tool 102. The gripper 108 is configured to engage the indexing feature 104 (e.g., make physical contact with the indexing feature form). The indexing feature 104 is suitably positioned relative to the fixture tool 102 such that at least a portion of the indexing feature 104 is physically accessible by the gripper 108. Conversely, the gripper 108 is suitably positioned relative to the fixture tool 102 such that at least a portion of the gripper 108 is physically accessible by the indexing feature 104. In the case where the gripper 108 is engaged to the indexing feature 104, the position of the gripper 108 (also referred to herein as the gripper position 114) FIG. 1 ) represents or corresponds to the indexing feature position 116 FIG. 1 . In other words, the gripper 108 positions the indexing feature 104 in the reference frame 216.

[0077] Referring to FIGS. 2-6 , in one example, the gripper 108 includes an articulating mechanism 230 and a gripping head 232 coupled to the working end of the articulating mechanism 230. The articulating mechanism 230 has multiple degrees of freedom and is configured to move the gripping head 232 linearly along and / or rotationally about at least one axis of the fixed coordinate system 112 in three-dimensional space.

[0078] The gripping head 232 is configured to engage the indexing feature 104. For example, the gripping head 232 is configured to grasp or otherwise securely hold at least a portion of the indexing feature 104. In the case where the gripping head 232 is engaged to the indexing feature 104, the gripper position 114 is the position of the gripping head 232 and represents or corresponds to the indexing feature position 116.

[0079] The articulating mechanism 230 includes at least one suitable drive motor (not shown) to drive the motion of the articulating mechanism 230, such as an electromechanical motor, a pneumatic motor, a hydraulic motor, etc. The articulating mechanism 230 is also configured to provide position data (e.g., the interface data 222) representative of the gripper position 114, for example, in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216. For example, the articulating mechanism 230 also includes at least one encoder (not shown) and / or at least one sensor (not shown) that converts the motion of the articulating mechanism 230 into an electrical signal representative of the gripper position 114. The articulating mechanism 230 includes other suitable electronic, mechanical, pneumatic, and hydraulic components (not shown). The articulating mechanism 230 operates under computer control, such as by the controller 110.

[0080] Referring to FIG. 2 and FIG. 4In one example, the articulation mechanism 230 is coupled to, or forms part of, the automated machine 128. In FIG. 4 In one example, the automated machine 128 is configured to move the gripper 108 relative to the operating cell 106 and the fixed tool 102 in at least one dimension of the fixed coordinate system 112. In other words, at least a portion of the range of motion or one or more degrees of freedom of the articulation mechanism 230 is provided by the automated machine 128. FIG. 2 In one example, the articulation mechanism 230 is separate from and independent of the automated machine 128. In this example, the full range of motion or each degree of freedom of the gripper 108 is provided by (e.g., is intrinsic to) the articulation mechanism 230.

[0081] Referring to FIG. 5 In one example, the articulation mechanism 230 is separate from and independent of the automated machine 128. In this example, the full range of motion or each degree of freedom of the gripper 108 is provided by (e.g., is intrinsic to) the articulation mechanism 230.

[0082] Referring to FIG. 6 In another example of the indexing apparatus 100, the interface device 220 FIG. 1 includes more than one gripper 108 (herein referred to as a plurality of grippers 108). In this example, the indexing apparatus 100 includes more than one indexing feature 104 (herein referred to as a plurality of indexing features 104). Each of the indexing features 104 is fixed relative to the fixed tool 102. Each of the grippers 108 is configured to engage and position a corresponding one of the indexing features 104.

[0083] Referring to FIGS. 1-6 The indexing apparatus 100 further includes a controller 110. The controller 110 is in communication with the grippers 108. The controller 110 is configured to position the fixed tool 102 relative to the operating cell 106 (e.g., relative to the reference frame 216) in accordance with the gripper position 114 of the gripper 108 with the gripper 108 engaged to the indexing feature 104.

[0084] In one example, the controller 110 is configured to determine the gripper position 114 of the gripper 108, for example, in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216. The controller 110 is further configured to determine the indexing feature position 116 of the indexing feature 104, for example, in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216, in accordance with the gripper position 114 of the gripper 108. The controller 110 is further configured to determine the fixed tool position 118 of the fixed tool 102, for example, in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216, in accordance with the indexing feature position 116 of the indexing feature 104.

[0085] In one example, controller 110 is configured to represent digital model 120 (representing fixing tool 102 and transposition feature 104) FIG. 1 The controller 110 is also configured to convert the model position 126 of the digital model 120 registered to the indexing feature position 116 into the fixed tool position 118 of the fixed tool 102.

[0086] FIG. 7 An example of input 234 provided to controller 110 during positioning and rotation operations and an example of output 236 generated by controller 110 are illustrated. In one example, gripper position data 238 is provided to controller 110 by gripper 108. Gripper position data 238 is interface data 222 ( FIG. 1 Example of gripper position data 238. In one example, gripper position data 238 is generated by an encoder, sensor, other relative positioning device, or a combination thereof, and represents gripper 108 ( FIG. 3 The actual physical position (gripper position 114) relative to reference frame 216. Controller 110 processes gripper position data 238 and determines gripper position 114 based on gripper position data 238. Controller 110 then processes gripper position 114 and determines rotation feature position 116 based on gripper position 114.

[0087] refer to FIGS. 2-6 In one example, when the gripper 108 (e.g., gripper head 232) engages with the indexing feature 104, there is at least one contact point between the gripper 108 and the indexing feature 104. This contact point has XYZ coordinates common to both the gripper 108 and the indexing feature 104. Gripper position data 238 ( FIG. 16 The coordinates (XYZ) represent the contact points of the gripper 108, and the gripper position 114 is described by the XYZ coordinates of the contact points of the gripper 108. The controller 110 converts the XYZ coordinates of the contact points of the gripper 108 into the XYZ coordinates of the corresponding contact points of the indexing feature 104. Then, the controller 110 determines the indexing feature position 116 as described by the XYZ coordinates of the contact points of the indexing feature 104.

[0088] In one example, the gripper 108 (e.g., gripper head 232) and the indexing feature 104 include multiple contact points. Therefore, the gripper position 114 is described by the XYZ coordinates of the multiple contact points of the gripper 108, and the indexing feature position 116 is described by the XYZ coordinates of the corresponding multiple contact points of the indexing feature 104.

[0089] It should be noted that increasing the number of contact points between the gripper 108 and the indexing feature 104 provides a greater number of XYZ coordinate data points for processing, which in turn increases the accuracy of the indexing feature location 116 and the fixed tool location 118 during data point alignment of the indexing operation. In one example, the gripper 108 (e.g., the gripper head 232) and the indexing feature 104 include at least three contact points.

[0090] Briefly referring to FIG. 8A 、 FIG. 8B 、 FIG. 9A and FIG. 9B , in one example, the gripper 108 (e.g., the gripper head 232) includes at least one contact indexing 148( FIG. 8A and FIG. 9A ) and the indexing feature 104 includes at least one interface indexing 146( FIG. 8B and FIG. 9B ). With the gripper 108 (e.g., the gripper head 232) engaged to the indexing feature 104, the contact indexing 148 engages the interface indexing 146 such that there is at least one contact point between the contact indexing 148 and the interface indexing 146. This contact point has XYZ coordinates common to both the contact indexing 148 and the interface indexing 146. The gripper position data 238 represents the XYZ coordinates of the contact point of the contact indexing 148 and the gripper position 114 is described by the XYZ coordinates of the contact point of the contact indexing 148.

[0091] The controller 110 converts the XYZ coordinates of the contact point of the contact indexing 148 to the XYZ coordinates of the corresponding contact point of the interface indexing 146. The controller 110 determines the indexing feature location 116 as described by the XYZ coordinates of the contact point of the interface indexing 146.

[0092] Generally, the gripper 108 (e.g., the gripper head 232) includes a plurality of contact indexings 148 and the indexing feature 104 includes a plurality of interface indexings 146, which in turn provides a plurality of contact points. Accordingly, the gripper position data 238( FIG. 7 ) represents the XYZ coordinates of the plurality of contact points of the contact indexings 148 of the gripper 108. The gripper position 114 is described by the XYZ coordinates of the contact points of the contact indexings 148 of the gripper 108. The indexing feature location 116 is described by the XYZ coordinates of the corresponding plurality of contact points of the interface indexings 146.

[0093] In one example, the gripper 108 (e.g., the gripper head 232) includes at least three contact index points 148, and the index feature 104 includes at least three interface index points 146, which results in at least three contact points. In other examples, the gripper 108 (e.g., the gripper head 232) can include a fewer number or a greater number of contact index points 148, and the index feature 104 can include a fewer number or a greater number of interface index points 146.

[0094] It is noted that increasing the number of contact index points 148 and interface index points 146 increases the number of contact points between the gripper 108 and the index feature 104, which in turn provides a greater number of XYZ coordinate data points for processing, which in turn increases the accuracy of the index feature position 116 and the fixed tool position 118 during data point alignment of the indexing operation.

[0095] Referring again to FIG. 7 , the controller 110 is configured to register the digital model 120 representing the fixed tool 102 and the index feature 104 to the index feature position 116 and determine the model position 126. In one example, the controller 110 is configured to overlap and align the digital model 120 with the XYZ coordinates describing the index feature position 116 within the frame of reference 216. The digital model 120 includes data points representing the contact points of the index feature 104. For example, the digital model 120 includes data points representing the interface index points 146 of the index feature 104. In one example, the controller 110 performs a best fit operation (e.g., executes a best fit algorithm) to align the data points representing the contact points of the index feature 104 (e.g., the data points representing the interface index points 146) with the data points representing the XYZ coordinates describing the index feature position 116. In one example, the best fit operation includes a rigid point cloud transformation operation.

[0096] With the digital model 120 registered and aligned to the index feature position 116, the controller 110 is configured to convert the model position 126 to a fixed tool position 118 of the fixed tool 102, e.g., relative to the frame of reference 216. For example, the fixed tool position 118 is assumed to be within tolerance of the model position 126. Thus, the fixed tool position 118 represents the instant (e.g., current, real-time) position of the fixed tool 102, and thus the workpiece 170, relative to the operation cell 106 and the automated machine 128.

[0097] With the fixed tool position 118 known, the automated machine 128 is indexed or "zeroed" relative to the fixed tool position 118 and follows a predetermined tool path to perform manufacturing operations on the workpiece 170. The automated machine 128 is indexed based on the fixed tool position 118 relative to the fixed tool 102, and thus relative to the workpiece 170. The geometry of the workpiece 170 and the known position of the workpiece 170 relative to the fixed tool 102 are incorporated in and accounted for by the programmed tool path of the automated machine 128.

[0098] Referring to FIG. 1 and FIG. 2 In one example, the indexing apparatus 100 includes the automated machine 128. The automated machine 128 is located in the operating cell 106 and is in communication with the controller 110. The controller 110 is configured to index the automated machine 128 relative to the fixed tool position 118 of the fixed tool 102.

[0099] Referring to FIG. 2 and FIGS. 4-6 In one example, the automated machine 128 includes a gantry 134. The gantry 134 is configured to provide at least a portion of the range of motion of the automated machine 128 or to provide one or more degrees of freedom to the automated machine 128. In one example, a robotic arm 226 is coupled to the gantry 134. In one example, the gantry 134 is an overhead gantry that is movable within the operating cell 106 to move the robotic arm 226 in at least one dimension of the fixed coordinate system 112. In this example, the fixed tool 102 and thus the workpiece 170 are moved to a work location 258 within the operating cell 106 and the gantry 134 and / or the robotic arm 226 are moved relative to the fixed tool 102 such that the end effector 228 follows along the predetermined tool path.

[0100] In another example (not shown), the robotic arm 226 is a standalone robot that has a fixed base within the operating cell 106. In this example, the fixed tool 102 and thus the workpiece 170 are moved to a work location 258 within the operating cell 106 and the robotic arm 226 is moved relative to the fixed tool 102 such that the end effector 228 travels along the predetermined tool path.

[0101] While the illustrated example of the indexing apparatus 100 shows only one automated machine 128 (e.g., one robotic arm 226 with one end effector 228) for performing manufacturing operations on the workpiece 170 in the operating cell 106, in other examples, the indexing apparatus 100 can have any number of additional automated machines 128 (e.g., additional robotic arms 226 and / or additional end effectors 228).

[0102] Referring to FIG. 1 and FIG. 2 In one example, the manufacturing operation includes a pre-cured composite assembly operation or other additive manufacturing operation performed on a pre-cured composite material, such as a composite layup operation and / or a composite lamination operation. In this example, the workpiece 170 includes a pre-cured composite laminate (e.g., a ply of a pre-impregnated composite material). The fixture tool 102 includes or takes the form of a mandrel 130. The mandrel 130 is configured to support the composite laminate (workpiece 170). The automated machine 128 is configured to perform a pre-cured manufacturing operation on the composite laminate (workpiece 170). For example, the automated machine 128 includes or takes the form of an automated fiber placement machine 132 FIG. 1 ) or takes the form of an automated fiber placement machine.

[0103] In one or more other examples, the manufacturing operation includes other additive manufacturing operations, such as assembly operations, or subtractive manufacturing operations, such as machining operations. In such examples, the workpiece 170 is one of a post-cured composite structure, a metal structure, a plastic structure, or other non-composite structure. The fixture tool 102 includes at least one retention feature 260 FIG. 1 ) configured to secure the workpiece 170 to the fixture tool 102 during movement to the operation cell 106 and during the manufacturing operation. The automated machine 128 is configured to perform at least one of an additive manufacturing operation and a subtractive manufacturing operation on the workpiece 170. In one example, the automated machine 128 is configured to perform a post-cured manufacturing operation on the post-cured composite structure. For example, the automated machine 128 includes or takes the form of any suitable machine tool 270 FIG. 1 ) or takes the form of a machine tool.

[0104] In one or more examples, any of the various manufacturing operations described herein are part of a continuous flow manufacturing process. For example, the fixture tool 102 and the workpiece 170 are pulsed to one of a plurality of operation cells that form a continuous flow manufacturing system. At any given operation cell of the plurality of operation cells, the manufacturing operation forms part of the continuous flow manufacturing process. In one example, the manufacturing operation includes placing one or more plies of a pre-cured composite material to partially form a composite laminate. In one example, the manufacturing operation includes assembling or installing a secondary structure to a post-cured composite structure or non-composite structure. In one example, the manufacturing operation includes machining one or more features in a post-cured composite structure or non-composite structure.

[0105] In one example, the fixture tool 102 is moved to the work location 258 and, as described above, the fixture tool 102 and the workpiece 170 are positioned (e.g., fixture tool position 118) using the gripper 108 and the indexing feature 104. Based on the fixture tool position 118 (e.g., the position of the fixture tool 102 and the position of the workpiece 170 relative to the fixture tool 102), the automated fiber placement machine 132 lays up and / or consolidates at least a portion of at least one ply of the stack of composite material.

[0106] Referring to FIG. 2 and FIGS. 4-6 In one example, the indexing apparatus 100 includes a drive assembly 138 coupled to the gripper 108. The drive assembly 138 is configured to move the gripper 108 relative to the reference frame 216, for example, in at least one dimension of the fixed coordinate frame 112. In one example, the drive assembly 138 is coupled to or forms a part of the articulation mechanism 230 of the gripper 108, for example, in examples where the gripper 108 is decoupled from the automated machine 128, as shown in FIGS. 2A and 2B. FIG. 5 and FIG. 6 In another example, the drive assembly 138 is coupled to or formed by the automated machine 128, for example, in examples where the gripper 108 is coupled to the automated machine 128, as shown in FIGS. 3A and 3B. FIG. 2 and FIG. 4

[0107] Referring to FIG. 1 In one example, the gripper 108 is configured to move the fixture tool 102 inside the work envelope 140 of the operating cell 106. In one example, the fixture tool 102 and the workpiece 170 are moved to an initial, pre-work location, for example, a location proximate (e.g., at or near) the work location 258 (e.g., outside the operating cell 106). The gripper 108, operating under computer control, is moved into engagement with the indexing feature 104. While engaged to the indexing feature 104, the gripper 108 moves the fixture tool 102 and the workpiece 170 to the work location 258 (e.g., inside the operating cell 106). In this manner, as described above, the fixture tool 102 and the workpiece 170 are moved to the work location 258 while the fixture tool position 118 is determined. This combined operation further improves the cycle time of the manufacturing operation by enabling the movement operation of the fixture tool 102 and the workpiece 170 and the positioning operation of the fixture tool 102 and the workpiece 170 to be performed substantially simultaneously.

[0108] ​In another example, the indexing apparatus 100 includes a separate movement mechanism (not shown) that is separate from the gripper 108 and is configured to move the fixture tool 102 to the work position 258. In this example, the fixture tool 102 and the workpiece 170 are moved to a pre-work position, and the separate movement mechanism, operating under computer control, moves the fixture tool 102 and the workpiece 170 to the work position 258.

[0109] FIG. 8A 、 FIG. 8B 、 FIG. 9A and FIG. 9B An example of the gripper 108 and the indexing feature 104 is shown schematically. In one example, the gripper 108 (e.g., the gripper head 232) includes a jaw assembly 144 FIG. 8A and FIG. 9A . The jaw assembly 144 is configured to grip, grasp, clamp, or otherwise securely hold at least a portion of the indexing feature 104 FIG. 8B and FIG. 9B . In one example, the indexing feature 104 includes a plate 150 that is coupled to and extends from the fixture tool 102 FIG. 8B . The contact indexing 148 FIG. 8A and FIG. 9A and the interface indexing 146 FIG. 8B and FIG. 9B are configured to contact and mate with each other when the gripper 108 (e.g., the jaw assembly 144) properly engages the indexing feature 104 (e.g., the plate 150).

[0110] Referring to FIG. 8A and FIG. 8B , in one example, the jaw assembly 144 includes a first jaw and a second jaw. The first jaw and the second jaw are movable relative to each other to selectively engage (e.g., grip) the plate 150. In one example, the jaw assembly 144 includes a first (e.g., upper) jaw that is fixed and a second (e.g., lower) jaw that is movable relative to the first jaw. In one example, each jaw of the jaw assembly 144 has a generally flat engagement surface that is configured to make secure contact with a corresponding one of the opposing flat engagement surfaces of the plate 150. Other configurations of the jaw assembly 144 and the plate 150 are also contemplated.

[0111] In one example, the contact indexing 148 FIG. 8A is coupled to or disposed on the jaw assembly 144, and the interface indexing 146 FIG. 8BThe contact index 148 is coupled to or disposed on the plate 150. The contact index 148 is suitably positioned and configured to engage the interface index 146 when the jaw assembly 144 clamps the plate 150. In one example, the contact index 148 is located on and protrudes from an engagement surface of one of the jaws (e.g., the upper jaw) of the jaw assembly 144, and the interface index 146 is located on and protrudes from one of the engagement surfaces of the plate 150.

[0112] In one example, the contact index 148 includes or takes the form of at least one contact structure 154. The interface index 146 includes or takes the form of at least one interface structure 152. In one example, the interface structure 152 and the contact structure 154 have complementary geometry and dimensions such that when the clamp head 232 properly engages the index feature 104, a corresponding surface of the contact structure 154 (e.g., forming the contact index 148) and a corresponding surface of the interface structure 152 (e.g., forming the interface index 146) are in contact. Each of the contact structure 154 and the interface structure 152 includes or takes the form of any of a variety of structural configurations or arrangements.

[0113] In one example, the contact structure 154 and the interface structure 152 include or take the form of a plurality of mating and complementary point structures. In the illustrated example, the contact structure 154 includes or takes the form of a protrusion formed on (e.g., protruding from) a surface of the clamp head 232, and the interface structure 152 includes or takes the form of a hole formed in (e.g., depending from) a surface of the plate 150. In this example, the interface structure 152 is configured to receive and mate with at least a portion of the contact structure 154. In another example, this arrangement can be reversed. For example, the contact structure 154 includes or takes the form of a hole, and the interface structure 152 includes or takes the form of a protrusion. As examples, the protrusion can be or take the form of a pin, a spring-loaded ball bearing, or other protruding body, and the hole can be or take the form of a bore, a detent, a recess, or other opening.

[0114] Referring to FIG. 9A and FIG. 9BIn another example, the interface structure 152 of the interface index 146 includes or takes the form of a tool ball that protrudes from the plate 150. The contact structure 154 of the contact index 148 includes or takes the form of a mating tool hole formed by the jaw assembly 144 and configured to receive and mate with the tool ball when the clamping head 232 properly engages the plate 150. In another example, this arrangement can be reversed. For example, the contact structure 154 includes or takes the form of a tool ball, and the interface structure 152 includes or takes the form of a tool hole.

[0115] Other structural configurations and / or arrangements of the contact index 148 (e.g., the contact structure 154) and the interface index 146 (e.g., the interface structure 152) are also contemplated, such as mating and complementary cup-cone configurations, etc.

[0116] In general, any suitable configuration or arrangement of the contact index 148 and the interface index 146 can be used such that there are at least three points of contact between the clamp 108 and the index feature 104 that can be used to generate at least three data points representing at least three XYZ coordinates of the index feature 104. In most cases, three data points are sufficient to generate a complete three-dimensional position of the fixture tool 102 during the above-described positioning and indexing operations.

[0117] In one example, the XZY coordinate positions of at least two of the contact index 148 (e.g., at least two of the contact structure 154) are different in at least two dimensions of the fixed coordinate system 112. Similarly, the XZY coordinate positions of at least two of the interface index 146 (e.g., at least two of the interface structure 152) are different in at least two dimensions of the fixed coordinate system 112.

[0118] In an example implementation of the above-described positioning and indexing operations, the fixture tool 102, and thus the workpiece 170, is moved to a work position 258 in order to engage the index feature 104 by the clamp 108. With the fixture tool 102 in the work position 258, the position of the index feature 104 relative to the reference frame 216 is generally known, or estimated within acceptable tolerances, to enable the clamp 108 to be moved under computer control relative to the index feature 104 to a pre-engagement position. The controller 110 then performs a search operation in which the clamp 108 is incrementally moved along a predetermined search path to find the interface index 146 and to align and mate the contact index 148 with the interface index 146. With the contact index 148 and the interface index 146 properly aligned and mated with each other, the contact index 148 and the interface index 146 share a point of contact, and the positioning and indexing operations are performed as described above.

[0119] Referring to FIG. 8A And FIG. 9A In one example, the gripper 108 includes at least one engagement sensor 240. The engagement sensor 240 is configured to determine when the gripper 108 is properly aligned with and engaged with the indexing feature 104, e.g., when the contact indexing 148 and interface indexing 146 are properly aligned and mated with each other. The engagement sensor 240 includes or takes the form of any of various types of suitable sensors, such as a depth gauge, a pressure sensor, a tool probe, a displacement sensor, etc.

[0120] Referring to FIGS. 1-6 In one example, the indexing apparatus 100 includes a vehicle 160. The vehicle 160 is configured to support the fixture 102. The vehicle 160 is also configured to move the fixture 102 relative to the operating unit 106. In one example, the vehicle 160 is configured to move the fixture 102, and thus the workpiece 170, to a work position 258 at which the gripper 108 engages the indexing feature 104 to perform the above-described positioning and indexing operations. In another example, the vehicle 160 is configured to move the fixture 102, and thus the workpiece 170, relative to the operating unit 106 to a pre-work position at which the gripper 108 engages the indexing feature 104 to perform the above-described movement, positioning, and indexing operations.

[0121] Referring to FIG. 1 In one example, the vehicle 160 includes or takes the form of an automated guided vehicle 162. The automated guided vehicle 162 is configured to move autonomously under computer control along a predetermined travel path. In this example, the operating unit 106 can include one or more of sensors, guide tapes, guide wires, laser targets, and any other suitable navigation mechanisms for moving the automated guided vehicle 162 along the predetermined travel path. In this example, the automated guided vehicle 162 moving along the predetermined travel path is configured to move the fixture 102 to the work position 258 (or the pre-work position) so that the gripper 108 finds and engages the indexing feature 104, as described above.

[0122] Referring to FIG. 1 And FIG. 2 In one example, the vehicle 160 includes or takes the form of a cart 164. The cart 164 is configured to travel along a track 166 that extends through the operating unit 106. In this example, the cart 164 moving along the track 166 is configured to move the fixture 102 to the work position 258 (or the pre-work position) so that the gripper 108 finds and engages the indexing feature 104, as described above.

[0123] In one example, the track 166 is arranged such that the Z coordinate of the fixture tool 102, and thus the index feature 104, is fixed and remains constant as the cart 164 travels along the track 166 to the work location 258. In this example, the positioning operation performed by the gripper 108 only needs to determine the XY coordinates of the point of contact between the gripper 108 and the index feature 104.

[0124] Referring to FIG. 1 and FIG. 2 In one example, the manufacturing system 168 includes the operation cell 106 and the automated machine 128. The automated machine 128 is located in the operation cell 106 and is configured to perform at least one manufacturing operation. The manufacturing system 168 also includes the fixture tool 102. The fixture tool 102 is configured to support the workpiece 170 and is movable relative to the operation cell 106. The manufacturing system 168 also includes the index feature 104. The index feature 104 is fixed relative to the fixture tool 102. For example, the index feature 104 is coupled to the fixture tool 102.

[0125] The manufacturing system 168 also includes the gripper 108. The gripper 108 is configured to engage the index feature 104. The manufacturing system 168 also includes the controller 110. The controller 110 is in communication with the gripper 108 and the automated machine 128. The controller 110 is configured to position the fixture tool 102 relative to the operation cell 106 according to a gripper position 114 of the gripper 108 engaged with the index feature 104. The controller 110 is also configured to index the automated machine 128 relative to a fixture tool position 118 of the fixture tool 102.

[0126] Referring to FIG. 1 and FIG. 7 In one example of the manufacturing system 168, the controller 110 is configured to determine the gripper position 114 of the gripper 108 in at least one dimension of the fixed coordinate system 112. The controller 110 is also configured to determine the index feature position 116 of the index feature 104 in at least one dimension of the fixed coordinate system 112 according to the gripper position 114 of the gripper 108. The controller 110 is also configured to determine the fixture tool position 118 of the fixture tool 102 in at least one dimension of the fixed coordinate system 112 according to the index feature position 116 of the index feature 104. The controller 110 is also configured to register a digital model 120 representing the fixture tool 102 and the index feature 104 to the index feature position 116 of the index feature 104 and to convert a model position 126 of the digital model 120 registered to the index feature position 116 to the fixture tool position 118 of the fixture tool 102.

[0127] Referring to FIGS. 1-3In one example of the manufacturing system 168, the fixture 102 includes a mandrel 130 configured to support the composite layup, and the automated machine 128 includes an automated fiber placement machine 132 configured to perform at least one composite layup or plating operation.

[0128] Referring to FIG. 2 and FIG. 4 In one example of the manufacturing system 168, the clamp 108 is coupled to the automated machine 128, and the automated machine 128 is configured to move the clamp 108 relative to the reference frame 216 in at least one dimension of the fixed frame 112. Referring to FIG. 5 and FIG. 6 In one example, the clamp 108 is configured to move independently of the automated machine 128. Referring to FIGS. 2-6 In one example, the clamp 108 is configured to move the fixture 102 inside the working envelope 140 of the operational cell 106.

[0129] Referring to FIG. 8A , FIG. 8B , FIG. 9A and FIG. 9B In one example of the manufacturing system 168, the indexing feature 104 includes at least one interface index 146. The clamp 108 includes at least one contact index 148 configured to engage the at least one interface index 146.

[0130] Referring to FIGS. 1-6 In one example, the manufacturing system 168 includes a vehicle 160. The vehicle 160 is configured to support the fixture 102 and move the fixture 102 relative to the operational cell 106.

[0131] Referring to FIG. 1 and FIG. 2 In one example, the manufacturing system 168 further includes a track 166. The track 166 extends through the operational cell 106. In this example, the vehicle 160 includes or takes the form of a cart 164 configured to travel along the track 166.

[0132] Referring to FIG. 10 In one example, the manufacturing system 168 includes a second operational cell 172. The manufacturing system 168 further includes a second automated machine 174. The second automated machine 174 is located in the second operational cell 172 and is configured to perform at least one manufacturing operation on a workpiece 170.

[0133] The manufacturing system 168 also includes a second gripper 176. The second gripper 176 is configured to engage the indexing feature 104. The controller 110 is in communication with the second gripper 176 and the second automated machine 174. The controller 110 is configured to position the stationary tool 102 relative to the second operating unit 172 based on a second gripper position 178 of the second gripper 176 that is engaged with the indexing feature 104. The controller 110 is also configured to index the second automated machine 174 relative to a second stationary tool position 180 of the stationary tool 102. Once indexed, the second automated machine 174 performs at least one manufacturing operation on the workpiece 170.

[0134] Referring generally to FIG. 1 , and specifically to FIGS. 11-13 , in another example, the indexing apparatus 100 includes a stationary tool 102. The stationary tool 102 is movable relative to the operating unit 106. The apparatus 100 also includes an indexing feature 104. The indexing feature 104 is fixed relative to the stationary tool 102. For example, the indexing feature 104 is located on the stationary tool 102.

[0135] In FIGS. 11-15 the illustrated example, the indexing feature 104 is coupled to or located on a top portion of the stationary tool 102. In other examples, the indexing feature 104 is coupled to or located on another portion (e.g., a side portion, a front portion, a rear portion, a bottom portion, etc.) of the stationary tool 102.

[0136] In one example, the indexing apparatus 100 includes a sensor 184. The sensor 184 is configured to detect (e.g., visually identify) the indexing feature 104. The indexing feature 104 is properly positioned relative to the stationary tool 102 such that at least a portion of the indexing feature 104 is visually accessible by the sensor 184. Conversely, the sensor 184 is properly positioned relative to the stationary tool 102 such that at least a portion of the sensor 184 is physically accessible by the indexing feature 104. In one example, the indexing feature 104 is located on or formed in an exposed outer surface of the stationary tool 102. The sensor 184 is configured to generate sensor data 186 FIG. 1 that is representative of a position of the indexing feature 104 (indexing feature position 116) FIG. 1 . In other words, the sensor 184 positions the indexing feature 104 in the reference frame 216.

[0137] Referring to FIGS. 11-13In one example, the sensor 184 includes an articulating mechanism 230 and a sensor head 242 coupled to a working end of the articulating mechanism 230. The articulating mechanism 230 is configured to move the sensor head 242 linearly and / or rotationally in three-dimensional space, such as along at least one axis of the fixed coordinate system 112.

[0138] The articulating mechanism 230 is also configured to provide position data (e.g., interface data 222) FIG. 1 representing a position of the sensor 184 (e.g., the sensor head 242) relative to the reference frame 216. In one example, the position data and the sensor data 186 are used to determine a position of the index feature location 116 relative to the reference frame 216. In one example, and for the purposes of this description, the position data of the sensor 184 relative to the reference frame 216 is merged with the sensor data 186.

[0139] Referring to FIG. 13 The sensor head 242 includes or takes the form of any of a variety of machine vision or computer vision systems configured to scan the fixed tool 102 and identify the index feature 104 from the scan. In one example, the sensor 184 (e.g., the sensor head 242) includes or takes the form of a video camera configured to capture still images or video (e.g., the sensor data 186) that visually represent the fixed tool 102 and the index feature 104. In another example, the sensor 184 (e.g., the sensor head 242) includes or takes the form of a laser scanner configured to project a laser onto the fixed tool 102 and collect the laser deflected back from the fixed tool 102, and generate sensor data 186 representing the index feature 104 from the collected laser.

[0140] In one example, the sensor data 186 represents or corresponds to the index feature location 116. In one example, the laser scanner is a two-dimensional laser scanner and the sensor data 186 represents a position of the index feature 104 in two dimensions (e.g., XY coordinates) of the fixed coordinate system. In another example, the laser scanner is a three-dimensional laser scanner and the sensor data 186 represents a position of the index feature in three dimensions (e.g., XYZ coordinates) of the fixed coordinate system.

[0141] Referring to FIG. 11 and FIG. 12 In one example, the articulating mechanism 230 is coupled to or forms a part of the automated machine 128. In FIG. 12In some examples, the automated machine 128 (e.g., for performing at least one manufacturing operation) is removed for illustrative clarity (e.g., for ease of illustration). FIG. 11 In this example, the automated machine 128 is configured to move the sensor 184 relative to the operating unit 106 and the fixed tool 102 in at least one dimension of the fixed coordinate system 112. In other words, at least a portion of the range of motion or one or more degrees of freedom of the articulating mechanism 230 are provided by the automated machine 128.

[0142] Referring to FIG. 13 In one example, the articulating mechanism 230 is separate and independent from the automated machine 128. In this example, the full range of motion or each degree of freedom of the sensor 184 is provided by (e.g., is inherent to) the articulating mechanism 230.

[0143] Referring to FIG. 14 In another example of the indexing apparatus 100, the interface device 220( FIG. 1 ) includes more than one sensor 184 (referred to herein as multiple sensors 184). In this example, the indexing apparatus 100 includes more than one indexing feature 104 (e.g., multiple indexing features 104). Each of the indexing features 104 is fixed relative to the fixed tool 102. Each of the sensors 184 is configured to scan, detect, and locate at least a portion of the indexing features 104 or a corresponding indexing feature of the multiple indexing features 104.

[0144] Referring to FIG. 1 and FIGS. 11-15 The indexing apparatus 100 also includes a controller 110. The controller 110 is in communication with the sensor 184. The controller 110 is configured to position the fixed tool 102 relative to the operating unit 106 according to the indexing feature position 116 of the indexing feature 104 identified by the sensor 184.

[0145] In one example, the controller 110 is configured to determine the indexing feature position 116 of the indexing feature 104 relative to the reference frame 216, for example, in at least one dimension of the fixed coordinate system 112, according to the sensor data 186 generated by the sensor 184. The controller 110 is also configured to determine the fixed tool position 118 of the fixed tool 102 relative to the reference frame 216, for example, in at least one dimension of the fixed coordinate system 112, according to the indexing feature position 116 of the indexing feature 104.

[0146] In one example, the controller 110 is configured to determine the fixed tool position 118 of the fixed tool 102 relative to the reference frame 216, for example, in at least one dimension of the fixed coordinate system 112, according to the sensor data 186 generated by the sensor 184. The controller 110 is also configured to determine the indexing feature position 116 of the indexing feature 104 relative to the reference frame 216, for example, in at least one dimension of the fixed coordinate system 112, according to the fixed tool position 118 of the fixed tool 102. FIG. 1) to the index feature position 116. The controller 110 is also configured to convert a model position 126 of the digital model 120 that is registered to the index feature position 116 to a fixture position 118 of the fixture tool 102.

[0147] FIG. 16 Examples of inputs 234 provided to the controller 110 and outputs 236 produced by the controller 110 during the positioning and indexing operations are schematically illustrated. In one example, sensor data 186 is provided to the controller 110 from the sensor 184. The sensor data 186 is an example of the interface data 222( FIG. 1 ) In one example, the sensor data 186 (e.g., the interface data 222) also includes position data that represents an actual physical position of the sensor 184 (e.g., the sensor head 242) FIG. 13 ) relative to the reference frame 216, e.g., as produced by an encoder, a sensor, other relative positioning device, or combination thereof. The controller 110 processes the sensor data 186 and determines the index feature position 116 based on the sensor data 186.

[0148] Referring to FIGS. 11-15 , in one example, the sensor 184 (e.g., the sensor head 242) is moved along a scan path relative to the fixture tool 102 and scans at least a portion of the fixture tool 102 that includes the index feature 104. The sensor 184 can collect a sufficient number of data points of the sensor data 186 FIG. 16 ) to locate the index feature 104 in a single pass, or possibly multiple passes. The controller 110 is configured to identify and extract data points that represent the index feature 104. The controller 110 then determines XYZ coordinates of the data points that represent the index feature 104 relative to the reference frame 216. The controller 110 then determines the index feature position 116 as described by the XYZ coordinates of the data points that represent the index feature 104 in the sensor data 186.

[0149] The index feature 104 includes a structure that is visually perceptible and / or computationally distinguishable from surrounding surface areas of the fixture tool 102. For example, the index feature 104 includes a structural configuration that is suitable for computational perception and identification, e.g., in point cloud processing operations performed on multiple data points of the sensor data 186. The index feature position 116 is described by the XYZ coordinates of the multiple data points of the sensor data 186 that represent the index feature 104.

[0150] It should be noted that increasing the number of data points in the sensor data 186 representing the index feature 104 provides a greater number of XYZ coordinate data points for processing, which in turn improves the accuracy of the index feature position 116 and the fixed tool position 118 during data point alignment of the indexing operation.

[0151] The controller 110 is configured to register the digital model 120 representing the fixed tool 102 and the index feature 104 to the index feature position 116 and determine a model position 126. In one example, the controller 110 is configured to overlap and align the digital model 120 with the XYZ coordinates describing the index feature position 116 within the frame of reference 216. The digital model 120 includes data points representing the index feature 104. In one example, the controller 110 performs a best fit operation (e.g., executes a best fit algorithm) to align the data points representing the index feature 104 with data points representing the XYZ coordinates describing the index feature position 116. In one example, the best fit operation includes a rigid point cloud transformation operation.

[0152] With the digital model 120 registered and aligned to the index feature position 116, the controller 110 is configured to convert the model position 126 to a fixed tool position 118 of the fixed tool 102, e.g., relative to the frame of reference 216. For example, the fixed tool position 118 is assumed to be within tolerance of the model position 126. Thus, the fixed tool position 118 represents the instant (e.g., current, real-time) position of the fixed tool 102, and thus the workpiece 170, relative to the operation cell 106 and the automated machine 128.

[0153] With the fixed tool position 118 known, the automated machine 128 is indexed or “zeroed” relative to the fixed tool position 118 and follows a predetermined tool path to perform a manufacturing operation on the workpiece 170. The automated machine 128 is indexed relative to the fixed tool 102 based on the fixed tool position 118, and thus relative to the workpiece 170. The geometry of the workpiece 170 and the known position of the workpiece 170 relative to the fixed tool 102 are incorporated in and accounted for by the programmed tool path of the automated machine 128.

[0154] Referring to FIG. 1 and FIG. 11 In one example, the indexing apparatus 100 includes an automated machine 128. The automated machine 128 is located in the operation cell 106 and is in communication with the controller 110. The controller 110 is configured to index the automated machine 128 relative to the fixed tool position 118 of the fixed tool 102.

[0155] Referring to FIG. 11 , FIG. 12 ,FIG. 14 and FIG. 15 In one example, the automated machine 128 includes a gantry 134. In this example, the fixture tool 102, and thus the workpiece 170, is moved to the work location 258 within the operation cell 106, and the gantry 134 and / or the robotic arm 226 coupled to the gantry 134 is moved relative to the fixture tool 102 such that the end effector 228 follows along the predetermined tool path.

[0156] In another example (not shown), the robotic arm 226 is a standalone robot having a fixed base within the operation cell 106. In this example, the fixture tool 102, and thus the workpiece 170, is moved to the work location 258 within the operation cell 106, and the robotic arm 226 is moved relative to the fixture tool 102 such that the end effector 228 follows along the predetermined tool path.

[0157] While the illustrated example of the indexing apparatus 100 shows only one automated machine 128 (e.g., one robotic arm 226 having one end effector 228) for performing manufacturing operations on the workpiece 170 in the operation cell 106, in other examples, the indexing apparatus 100 can have any number of additional automated machines 128 (e.g., additional robotic arms 226 and / or additional end effectors 228).

[0158] Referring to FIG. 1 and FIG. 11 In one example, the manufacturing operations include pre-cured composite assembly operations, such as a composite layup operation and / or a composite lamination operation. In this example, the workpiece 170 includes a composite laminate (e.g., a layup of composite material). The fixture tool 102 includes or takes the form of a mandrel 130. The mandrel 130 is configured to support the composite laminate. The automated machine 128 includes or takes the form of an automated fiber placement machine 132.

[0159] In one example, the fixture tool 102 is moved to the work location 258, and as described above, the instantaneous position of the fixture tool 102 and the workpiece 170 (e.g., the fixture tool position 118) is determined using the sensor 184 and the indexing feature 104. Based on the fixture tool position 118 (e.g., the position of the fixture tool 102 and the position of the workpiece 170 relative to the fixture tool 102), the automated fiber placement machine 132 lays up and / or consolidates at least a portion of at least one layer of the stack of composite sheets.

[0160] In one or more other examples (not explicitly shown), the manufacturing operation includes another assembly operation or a machining operation. In such examples, the workpiece 170 can be a post-cured composite workpiece, a metal workpiece, a plastic workpiece, or other non-composite workpiece. The fixture tool 102 includes suitable retention features 260 FIG. 1 configured to secure the workpiece 170 during movement to the operation cell 106 and during the manufacturing operation. The automated machine 128 includes or takes the form of any suitable machine tool.

[0161] Referring to FIG. 12 , FIG. 14 and FIG. 15 , in one example, the indexing apparatus 100 includes a drive assembly 138 coupled to the sensor 184. The drive assembly 138 is configured to move the sensor 184 (e.g., the sensor head 242) relative to the reference frame 216, such as in one or more dimensions of the fixed coordinate frame 112. In one example, the drive assembly 138 is coupled to or forms a part of the articulation mechanism 230 of the sensor 184, such as in examples where the sensor 184 is separate from the automated machine 128, as shown in FIG. 14 and FIG. 15 . In another example, the drive assembly 138 is coupled to or formed by the automated machine 128, such as in examples where the sensor 184 is coupled to the automated machine 128, as shown in FIG. 11 and FIG. 12 .

[0162] In one example, the indexing apparatus 100 includes a separate movement mechanism (not shown) configured to move the fixture tool 102 to the working position 258.

[0163] Referring to FIG. 13 , in one example, the indexing feature 104 includes at least one interface structure 192. In the example shown in FIG. 13 , the indexing feature 104 includes two interface structures 192. However, in other examples, the indexing feature 104 includes any number of interface structures 192.

[0164] In one example, the interface structure 192 is located on a surface 194 (e.g., an exposed surface) of the fixture tool 102. In other words, the interface structure 192 is suitably positioned so as to not be obscured by the workpiece 170 FIG. 13The interface structure 192 is suitably positioned so as to be visually accessible by the sensor 184 during the above-described positioning and indexing operations. The interface structure 192 comprises any of a variety of different structures that are visually perceptible and / or computationally discernible from a surface 194 of the fixture tool 102 that surrounds the indexing feature 104. FIGS. 17-20 Various examples of the interface structure 192 are schematically illustrated.

[0165] Referring to FIG. 17 In one example, in an example of the indexing feature 104, the interface structure 192 is continuous and extends longitudinally along the surface 194 (e.g., a top surface) of the fixture tool 102. In other words, the interface structure 192 can be a continuous interface structure. In one example, the interface structure 192 can be linear, as shown in FIG. 17 In another example, the interface structure 192 can be non-linear.

[0166] Referring to FIG. 18 In another example of the indexing feature 104, the interface structure 192 is discontinuous and extends longitudinally along the surface 194 of the fixture tool 102. In other words, the interface structure 192 can be a plurality of discontinuous interface point structures (e.g., also referred to herein as a plurality of interface structures 192). In one example, the plurality of interface structures 192 can be linearly arranged, as shown in FIG. 18 In another example, the plurality of interface structures 192 can be non-linearly arranged.

[0167] In one example, the interface structure 192 is a continuous groove formed in (e.g., overhanging from) the surface 194 of the fixture tool 102. In another example, the interface structure 192 is a continuous ridge formed on (e.g., protruding from) the surface 194 of the fixture tool 102. In another example, each of the plurality of interface structures 192 comprises a hole formed in (e.g., overhanging from) the surface 194. In another example, each of the plurality of interface structures 192 comprises a protrusion formed on (e.g., protruding from) the surface 194.

[0168] In the illustrated example, the indexing feature 104 comprises two interface structures 192. In other examples, the indexing feature 104 comprises any number of interface structures 192. Other structural configurations and / or arrangements of the interface structure 192 are also contemplated.

[0169] Referring to FIG. 19In another example, the interface structure 192 is formed by an edge of the fixture 102. In one example, the edge extends continuously and longitudinally along the fixture 102. In one example, the edge is formed by the intersection of two exposed surfaces 194 (e.g., a top surface and a side surface) of the fixture 102. In the illustrated example, the interface structure 192 of the indexing feature 104 includes, or is formed by, two edges of the fixture 102. In other examples, the interface structure 192 of the indexing feature 104 includes, or is formed by, any number of edges.

[0170] In another example, the interface structure 192 includes a combination of two or more types of structures, such as a groove, a ridge, a series of holes, a series of protrusions, and an edge. Various other configurations of the interface structure 192 are also contemplated.

[0171] In examples in which the indexing feature 104 includes two or more interface structures 192, the interface structures 192 (e.g., grooves, ridges, holes, protrusions, and edges) are not parallel to one another (e.g., are obliquely oriented to one another). The non-parallel arrangement of the interface structures 192 provides for non-parallel data points in the sensor data 186 that can be combined during processing to derive XYZ coordinates of the plurality of data points in more than one dimension of the fixed coordinate system 112 relative to the reference frame 216.

[0172] Referring to FIGS. 11-15 In one example, the indexing apparatus 100 includes a vehicle 160. The vehicle 160 is configured to support the fixture 102 and move the fixture 102 relative to the operations unit 106. In one example, the vehicle 160 is configured to move the fixture 102, and thus the workpiece 170, to a work location 258 at which the sensor 184 scans and detects (e.g., visually identifies) the indexing feature 104 to perform the positioning and indexing operations described above.

[0173] Referring to FIG. 1 In one example of the indexing apparatus 100, the vehicle 160 includes, or takes the form of, an automated guided vehicle 162. Referring to FIG. 1 and FIG. 11 In one example, the vehicle 160 includes, or takes the form of, a cart 164. The cart 164 is configured to travel along a track 166 that extends through the operations unit 106.

[0174] In one example, the track 166 is arranged such that the Z coordinate of the fixture 102, and thus the indexing feature 104, is fixed and remains constant as the cart 164 travels along the track 166 to the work location 258. In this example, the positioning operation performed by the sensor 184 only needs to determine the XY coordinates of the indexing feature 104.

[0175] Referring to FIG. 1 and FIG. 11 In another example, the manufacturing system 168 includes the operation cell 106 and the automated machine 128. The automated machine 128 is located in the operation cell 106 and is configured to perform at least one manufacturing operation. The manufacturing system 168 also includes the fixture 102. The fixture 102 is configured to support the workpiece 170 and is movable relative to the operation cell 106. The manufacturing system 168 also includes the indexing feature 104. The indexing feature 104 is fixed relative to the fixture 102. For example, the indexing feature 104 is located on the fixture 102.

[0176] The manufacturing system 168 also includes the sensor 184. The sensor 184 is configured to detect (e.g., visually identify) the indexing feature 104. The manufacturing system 168 also includes the controller 110 in communication with the sensor 184 and the automated machine 128. The controller 110 is configured to position the fixture 102 relative to the operation cell 106 according to the indexing feature location 116 of the indexing feature 104 identified by the sensor 184. The controller 110 is also configured to index the automated machine 128 relative to the fixture location 118 of the fixture 102.

[0177] Referring to FIG. 1 and FIG. 16 In one example of the manufacturing system 168, the controller 110 is configured to determine the indexing feature location 116 of the indexing feature 104 in at least one dimension of the fixed coordinate system 112 according to the sensor data 186 generated by the sensor 184. The controller 110 is also configured to determine the fixture location 118 of the fixture 102 in at least one dimension of the fixed coordinate system 112 according to the indexing feature location 116 of the indexing feature 104. The controller 110 is also configured to register the digital model 120 representing the fixture 102 and the indexing feature 104 to the indexing feature location 116 of the indexing feature 104; and convert the model location 126 of the digital model 120 registered to the indexing feature location 116 to the fixture location 118 of the fixture 102.

[0178] Referring to FIG. 1 , FIG. 11 and FIG. 13In one example of the manufacturing system 168, the stationary tool 102 includes a mandrel 130 configured to support the composite layup, and the automated machine 128 includes an automated fiber placement machine 132 configured to perform at least one composite layup or plating operation.

[0179] Referring to FIG. 11 and FIG. 12 In one example of the manufacturing system 168, the sensor 184 is coupled to the automated machine 128, and the automated machine 128 is configured to move the sensor 184 relative to the stationary tool 102 in at least one dimension of the fixed coordinate system 112. Referring to FIG. 14 and FIG. 15 In one example, the sensor 184 is configured to move independently of the automated machine 128.

[0180] Referring to FIG. 13 and FIGS. 17-19 In one example of the manufacturing system 168, the indexing feature 104 includes at least one interface structure 192 located on a surface 194 of the stationary tool 102. The interface structure 192 is visually detectable (e.g., perceptible and identifiable) by the sensor 184.

[0181] Referring to FIG. 1 and FIGS. 11-15 In one example, the manufacturing system 168 includes a vehicle 160. The vehicle 160 is configured to support the stationary tool 102 and move the stationary tool 102 relative to the operating unit 106.

[0182] Referring to FIG. 1 and FIG. 11 In one example, the manufacturing system 168 further includes a track 166. The track 166 extends through the operating unit 106. In this example, the vehicle 160 includes or takes the form of a cart 164 configured to travel along the track 166.

[0183] Referring to FIG. 20 In one example, the manufacturing system 168 includes a second operating unit 172. The manufacturing system 168 further includes a second automated machine 174. The second automated machine 174 is located in the second operating unit 172 and is configured to perform at least one manufacturing operation on the workpiece 170.

[0184] The manufacturing system 168 also includes a second sensor 198. The second sensor 198 is configured to detect (e.g., visually identify) the indexing feature 104. The controller 110 is in communication with the second sensor 198 and the second automated machine 174. The controller 110 is configured to position the stationary tool 102 relative to the second operating unit 172 based on a second indexing feature position 200 of the indexing feature 104 identified by the second sensor 198. The controller 110 is also configured to index the second automated machine 174 relative to a second stationary tool position 180 of the stationary tool 102. Once indexed, the second automated machine 174 performs at least one manufacturing operation on the workpiece 170.

[0185] Referring generally to FIG. 1 , and specifically to FIGS. 21-23 , in another example, the indexing apparatus 100 includes a stationary tool 102. The stationary tool 102 is movable relative to the operating unit 106. The indexing apparatus 100 also includes an indexing feature 104. The indexing feature 104 is fixed relative to the stationary tool 102. For example, the indexing feature 104 is formed by the stationary tool 102 or otherwise disposed on the stationary tool 102.

[0186] In FIGS. 21-23 the illustrated example, the indexing feature 104 is coupled to or on at least one side of the tool 102. In other examples, the indexing feature 104 is coupled to or on another portion (e.g., opposite side, front, back, top, bottom, etc.) of the stationary tool 102.

[0187] In one example, the indexing apparatus 100 includes a plurality of probes 202. The plurality of probes 202 is movable relative to the operating unit 106 and the stationary tool 102. The plurality of probes 202 is configured to engage (e.g., make physical contact with) the indexing feature 104. The indexing feature 104 is properly positioned relative to the stationary tool 102 such that at least a portion of the indexing feature 104 is physically accessible by the plurality of probes 202. Conversely, the plurality of probes 202 is properly positioned relative to the stationary tool 102 such that at least a portion of the plurality of probes 202 is physically accessible by the indexing feature 104. In the event the plurality of probes 202 engages the indexing feature 104, a plurality of positions of the plurality of probes 202 (also referred to herein as a plurality of probe positions 204) FIG. 1 ) represent or correspond to the indexing feature position 116 FIG. 1 ). In other words, the plurality of probes 202 positions the indexing feature 104 in the frame of reference 216.

[0188] Referring to FIGS. 21-23In one example of the indexing apparatus 100, the plurality of probes 202 forms part of a probe assembly 250 (e.g., the probe assembly 250 includes the plurality of probes 202). The probe assembly 250 includes a drive mechanism 252 coupled to each of the plurality of probes 202 associated with the probe assembly 250. The drive mechanism 252 is configured to move each of the plurality of probes 202 (e.g., also referred to collectively as probes 202 and individually as a probe 202) relative to the fixed tool 102 in at least one dimension of the fixed coordinate system 112. For example, the drive mechanism 252 is configured to linearly translate (e.g., extend and retract) each probe 202 in one dimension (e.g., the Y-direction) of the fixed coordinate system 112.

[0189] The drive mechanism 252 includes at least one suitable drive motor (not shown) to drive the movement of the probes 202, such as an electromechanical motor, a pneumatic motor, a hydraulic motor, etc. The probe assembly 250 is further configured to provide position data (e.g., the interface data 222) representative of a plurality of positions (e.g., a plurality of probe positions 204) of the probes 202 relative to the reference frame 216 in at least one dimension of the fixed coordinate system 112. For example, the probe assembly 250 further includes at least one encoder (not shown) and / or at least one sensor (not shown) that converts the movement of each probe 202 into an electrical signal representative of the probe position 204 of the corresponding probe 202. The probe assembly 250 further includes other suitable electronic, mechanical, pneumatic, and hydraulic components (not shown). The drive mechanism 252 operates under computer control, such as by the controller 110.

[0190] In FIG. 21 and FIG. 22 In one example, the indexing apparatus 100 includes two probe assemblies 250, for example, opposite each other, such that the probes 202 associated with each of the probe assemblies 250 engage corresponding indexing features 104 disposed, for example, on opposite sides of the fixed tool 102. In another example, the indexing apparatus 100 includes one probe assembly 250 such that the probes 202 associated with the probe assembly 250 engage the indexing features 104 disposed on the fixed tool 102.

[0191] Referring to FIG. 1 and FIGS. 21-23 The indexing apparatus 100 further includes the controller 110. The controller 110 is in communication with the plurality of probes 202. The controller 110 is configured to position the fixed tool 102 relative to the operating unit 106 based on the plurality of probe positions 204 of the plurality of probes 202 in the event the plurality of probes 202 are engaged to the indexing features 104.

[0192] In one example of the indexing device 100, a controller 110 is configured to determine, for example, multiple detector positions 204 of a plurality of detectors 202 relative to a reference frame 216 in at least one dimension of a fixed coordinate system 112. The controller 110 is also configured to determine, for example, an indexing feature position 116 of an indexing feature 104 relative to the reference frame 216 in at least one dimension of the fixed coordinate system 112 based on the multiple detector positions 204 of the plurality of detectors 202. The controller 110 is also configured to determine, for example, an anchoring tool position 118 of an anchoring tool 102 relative to the reference frame 216 in at least one dimension of the fixed coordinate system 112 based on the anchoring feature position 116 of the anchoring feature 104.

[0193] In one example, controller 110 is configured to represent digital model 120 (representing fixing tool 102 and transposition feature 104) FIG. 1 The controller 110 is also configured to convert the model position 126 of the digital model 120 registered to the indexing feature position 116 into the fixed tool position 118 of the fixed tool 102.

[0194] FIG. 24 An example of input 234 provided to controller 110 during positioning and rotation operations and an output 236 generated by controller 110 is illustrated schematically. In one example, detector position data 254 is provided to controller 110 by detector assembly 250. Detector position data 254 is interface data 222 ( FIG. 1 Example. In one example, detector position data 254 is generated by an encoder, sensor, other relative positioning device, or a combination thereof, and represents the actual physical position of multiple detectors 202 (detector position 204). FIG. 13 The controller 110 processes the detector position data 254 and determines the detector position 204 based on the detector position data 254. The controller 110 then processes the detector position 204 and determines the transposition feature position 116 based on the detector position 204.

[0195] refer to FIGS. 21-23 In one example, when detector 202 is engaged with transposition feature 104, there are multiple contact points between detector 202 and transposition feature 104. Each of these contact points has XYZ coordinates that are common to both detector 202 and transposition feature 104. Detector position data 254 ( FIG. 24represents XYZ coordinates of the contact points of the probes 202 (e.g., XYZ coordinates of the contact points of each probe 202), and the probe location 204 is described by the XYZ coordinates of the contact points of the probes 202. The controller 110 converts the XYZ coordinates of the contact points of the probes 202 to XYZ coordinates of the corresponding contact points of the indexing feature 104. The controller 110 then determines the indexing feature location 116 as described by the XYZ coordinates of the contact points of the indexing feature 104.

[0196] In one example, the probe assembly 250 includes at least two probes 202 that correspond to at least two contact points between the probes 202 and the indexing feature 104, which in turn provides at least two XYZ coordinates that describe the indexing feature location 116 of the indexing feature 104. In another example, the probe assembly 250 includes at least three probes 202 that correspond to at least three contact points between the probes 202 and the indexing feature 104, which in turn provides at least three XYZ coordinates that describe the indexing feature location 116 of the indexing feature 104. In another example, a combination of probes 202 from two or more probe assemblies 250 correspond to at least three contact points between the probes 202 and the indexing feature 104, which in turn provides at least three XYZ coordinates that describe the indexing feature location 116 of the indexing feature 104.

[0197] In one example, the multiple contact points are provided by probes 202 of one probe assembly 250 that engage the indexing feature 104 disposed on the fixture 102. In another example, some of the contact points are provided by probes 202 associated with a first probe assembly 250 that engage a first portion of the indexing feature 104 (or a first indexing feature 104) disposed on a first side (or first surface) of the fixture 102, and some of the contact points are provided by probes 202 associated with a second probe assembly 250 that engage a second portion of the indexing feature 104 (or a second indexing feature 104) disposed on a second side (or second surface) of the fixture 102.

[0198] It should be noted that increasing the number of contact points between the probes 202 and the indexing feature 104 (e.g., by increasing the number of probes 202 that engage the indexing feature 104) provides a greater number of XYZ coordinate data points for processing, which in turn improves the accuracy of the indexing feature location 116 and the fixture location 118 during data point alignment of the indexing operation.

[0199] In the illustrated example, the probe 202 (e.g., of the opposing probe assembly 250) is arranged to engage a portion of the index feature 104 (or a different index feature 104) disposed on an opposite side (e.g., side surface) of the fixture tool 102. In other examples (not illustrated), the probe 202 (e.g., from an additional or alternative probe assembly 250) is arranged to engage a portion of the index feature 104 (or a different index feature 104) disposed on another portion or surface (e.g., top, bottom, front, back, etc.) of the fixture tool 102.

[0200] Referring to FIG. 27 In one example, the probe 202 includes a contact index 148, and the index feature 104 includes an interface index 146. In the case where the probe 202 is engaged to the index feature 104, there is a contact point between the contact index 148 and the interface index 146. The contact point has XYZ coordinates that are common to both the contact index 148 and the interface index 146. The probe position data 254 represents the XYZ coordinates of the contact point of the contact index 148 of the probe 202, and the probe position 204 of the probe 202 is described by the XYZ coordinates of the contact point of the contact index 148 of the probe 202.

[0201] The controller 110 converts the XYZ coordinates of the contact point of the contact index 148 to the XYZ coordinates of a corresponding contact point of the interface index 146. The controller 110 determines the index feature position 116 as described by the XYZ coordinates of the contact point of the interface index 146.

[0202] In general, the plurality of probes 202 includes or forms a plurality of contact indexes 148, and the index feature 104 includes or forms a plurality of interface indexes 146, which in turn provides a plurality of contact points. Accordingly, the probe position data 254 FIG. 24 represents the XYZ coordinates of the plurality of contact points of the contact indexes 148 of the plurality of probes 202. The plurality of probe positions 204 is described by the XYZ coordinates of the contact points of the contact indexes 148 of the plurality of probes 202. The index feature position 116 is described by the XYZ coordinates of the corresponding plurality of contact points of the interface indexes 146.

[0203] It should be noted that increasing the number of contact indexes 148 and interface indexes 146 increases the number of contact points between the probe 202 and the index feature 104, which in turn provides a greater number of XYZ coordinate data points for processing, which in turn increases the accuracy of the index feature position 116 and the fixture position 118 during data point alignment of the indexing operation. In one example, the probe assembly 250 (e.g., the plurality of probes 202) includes at least three contact indexes 148, and the index feature 104 includes at least three interface indexes 146.

[0204] Referring again to FIG. 24 , the controller 110 is configured to register the digital model 120 representing the fixture tool 102 and the index feature 104 to the index feature location 116 and determine a model location 126. In one example, the controller 110 is configured to overlay and align the digital model 120 with the XYZ coordinates describing the index feature location 116 within the frame of reference 216. The digital model 120 includes data points representing contact points of the index feature 104. For example, the digital model 120 includes data points representing the interface index 146 of the index feature 104. In one example, the controller 110 performs a best fit operation (e.g., executes a best fit algorithm) to align the data points representing contact points of the index feature 104, such as the data points representing the interface index 146, with the data points representing the XYZ coordinates describing the index feature location 116. In one example, the best fit operation includes a rigid point cloud transformation operation.

[0205] With the digital model 120 registered and aligned to the index feature location 116, the controller 110 is configured to convert the model location 126 to a fixture tool location 118 of the fixture tool 102 relative to the frame of reference 216. For example, the fixture tool location 118 is assumed to be within tolerance of the model location 126. Thus, the fixture tool location 118 represents the instant (e.g., current, real-time) location of the fixture tool 102, and thus the workpiece 170, relative to the operation cell 106 and the automated machine 128.

[0206] With the fixture tool location 118 known, the automated machine 128 is indexed or “zeroed” relative to the fixture tool location 118 and follows the predetermined tool path to perform the manufacturing operation on the workpiece 170. The automated machine 128 is indexed relative to the fixture tool 102 based on the fixture tool location 118, and thus relative to the workpiece 170. The geometry of the workpiece 170 and the known location of the workpiece 170 relative to the fixture tool 102 are incorporated in and accounted for by the programmed tool path of the automated machine 128.

[0207] Referring to FIG. 1 and FIG. 21 , in one example, the indexing apparatus 100 includes the automated machine 128. The automated machine 128 is located in the operation cell 106. The automated machine 128 is in communication with the controller 110. The controller 110 is configured to index the automated machine 128 relative to the fixture tool location 118 of the fixture tool 102.

[0208] Referring to FIG. 22 and FIG. 23In one example, the automated machine 128 includes a gantry 134. In this example, the fixture tool 102, and thus the workpiece 170, is moved to the work location 258 within the operation cell 106, and the gantry 134 and / or a robotic arm 226 coupled to the gantry 134 is moved relative to the fixture tool 102 such that the end effector 228 travels along the predetermined tool path.

[0209] In another example (not shown), the robotic arm 226 is a standalone robot having a fixed base within the operation cell 106. In this example, the fixture tool 102, and thus the workpiece 170, is moved to the work location 258 within the operation cell 106, and the robotic arm 226 is moved relative to the fixture tool 102 such that the end effector 228 travels along the predetermined tool path.

[0210] While the illustrated example of the indexing apparatus 100 shows only one automated machine 128 (e.g., one robotic arm 226 having one end effector 228) for performing manufacturing operations on the workpiece 170 in the operation cell 106, in other examples, the indexing apparatus 100 can have any number of additional automated machines 128 (e.g., additional robotic arms 226 and / or additional end effectors 228).

[0211] Referring to FIG. 1 and FIG. 22 In one example, the manufacturing operations include pre-cure composite assembly operations, such as composite layup operations and / or composite lamination operations. In this example, the workpiece 170 includes a composite laminate (e.g., a layup of composite material). The fixture tool 102 includes or takes the form of a mandrel 130. The mandrel 130 is configured to support the composite laminate. The automated machine 128 includes or takes the form of an automated fiber placement machine 132.

[0212] In one example, the fixture tool 102 is moved to the work location 258, and as described above, the instantaneous position of the fixture tool 102 and the workpiece 170 (e.g., the fixture tool position 118) is determined using the plurality of probes 202 and the indexing feature 104. Based on the fixture tool position 118 (e.g., the position of the fixture tool 102 and the position of the workpiece 170 relative to the fixture tool 102), the automated fiber placement machine 132 lays up and / or consolidates at least a portion of at least one layer of the stack of composite sheet material.

[0213] In one or more other examples (not explicitly shown), the manufacturing operations include another assembly operation or a machining operation. In such examples, the workpiece 170 can be a post-cure composite workpiece, a metal workpiece, a plastic workpiece, or other non-composite workpiece. The fixture tool 102 includes suitable holding features 260 FIG. 1The retaining feature is configured to hold the workpiece 170 in place during movement to the operating unit 106 and during manufacturing operations. The automated machine 128 includes any suitable machine tool or takes any suitable form.

[0214] In one example, the indexing device 100 includes a separate moving mechanism (not shown) configured to move the fixing tool 102 to the working position 258.

[0215] FIG. 25 and FIG. 26 An example of the transposition feature 104 is shown schematically. FIG. 27 An example of a detector 202 and a transposition feature 104 is schematically shown. Typically, the transposition feature 104 includes at least one interface transposition 146. In one example, the interface transposition 146 is disposed (e.g., positioned or formed on) the surface 194 of the retaining tool 102. Each of the plurality of detectors 202 includes a contact transposition 148. FIG. 27 The contact transducer 148 is movable relative to at least one interface transducer 146. The contact transducer 148 is configured to engage the interface transducer 146 so that the detector 202 can locate the transducer feature 104.

[0216] refer to FIG. 27 In one example, each detector 202 includes a detector head 208. The detector 202 is configured to move relative to the fixed tool 102 in at least one dimension of the fixed coordinate system 112 to engage the detector head 208 with the indexing feature 104. In one example, each detector 202 includes a detector shaft 256. The detector head 208 is coupled to an end of the detector shaft 256. A drive mechanism 252 is configured to extend and retract the detector shaft 256 to move the detector head 208.

[0217] In one example, the interface shifter 146 includes or is formed of at least one interface structure 206 located on or 194 of the fixing tool 102. For example, the interface shifter 146 is formed by a portion of the interface structure 206, such as a portion of the surface of the interface structure 206. In one example, the contact shifter 148 includes or is formed of a detector head 208. In this example, the detector head 208 is the contact structure of the contact shifter 148. For example, the contact shifter 148 is formed by a portion of the detector head 208, such as a portion of the surface of the detector head 208.

[0218] In one example, the probe head 208 is configured to engage the interface structure 206 such that the contact index 148 contacts the interface index 146. The contact index 148 and the interface index 146 are configured to contact and mate with one another when the probe 202 (e.g., the probe head 208) properly engages the index feature 104 (e.g., the interface structure 206).

[0219] Referring to FIG. 25 In one example of the index feature 104, the interface structure 206 is continuous and extends longitudinally along the surface 194 (e.g., a side surface) of the fixture 102. In other words, the interface structure 206 can be a continuous interface structure. In one example, the interface structure 206 can be linear, as shown in FIG. 25 In another example, the interface structure 206 can be non-linear.

[0220] Referring to FIG. 26 In another example of the index feature 104, the interface structure 206 is discontinuous and extends longitudinally along the surface 194 of the fixture 102. In other words, the interface structure 206 can be a plurality of discontinuous interface point structures (e.g., also referred to herein as a plurality of interface structures 206). In one example, the plurality of interface structures 206 can be linearly arranged. In another example, the plurality of interface structures 206 can be non-linearly arranged, as shown in FIG. 26

[0221] In one example, the probe head 208 and the interface structure 206 have complementary geometries and dimensions such that, when the probe 202 properly engages the index feature 104, a corresponding surface of the probe head 208 (e.g., forming the contact index 148) and a corresponding surface of the interface structure 206 (e.g., forming the interface index 146) contact. Each of the probe head 208 and the interface structure 206 includes or takes the form of any of a variety of structural configurations.

[0222] ​In one example, the interface structure 206 is a continuous groove formed in (e.g., depending from) the surface 194 of the fixture tool 102. In this example, the probe head 208 is configured to be inserted into a portion of the interface structure 206. In another example, the interface structure 206 is a continuous ridge formed on (e.g., protruding from) the surface 194 of the fixture tool 102. In this example, the probe head 208 is configured to receive a portion of the interface structure 206. In another example, each of the plurality of interface structures 206 includes a hole formed in (e.g., depending from) the surface 194. In this example, the probe head 208 is configured to be inserted into the interface structure 206. In another example, each of the plurality of interface structures 206 includes a protrusion formed on (e.g., protruding from) the surface 194. In this example, the probe head 208 is configured to receive the interface structure 206.

[0223] Other structural configurations and / or arrangements of the contact features 148 (e.g., the probe heads 208) and the interface features 146 (e.g., the interface structures 206) are also contemplated.

[0224] In another example of the indexing feature 104, the interface structure 206 comprises or takes the form of at least one surface 194 (e.g., an exterior surface) of the fixture tool 102. In other words, the surface 194 of the fixture tool 102 is the interface structure 206 of the interface feature 146. Each of the plurality of probes 202 is configured to move the probe head 208 into contact with the surface 194 of the fixture tool 102. For example, the drive mechanism 252 extends the probe shaft 256 to move the probe head 208 into contact with the surface 194, and thus place the contact feature 148 formed by a portion of the surface of the probe head 208 into contact with the interface feature 146 formed by a portion of the surface 194 of the fixture tool 102.

[0225] Referring to FIG. 27 In one example of the indexing apparatus 100, the probe assembly 250 includes a displacement sensor 210. The displacement sensor 210 is in communication with each of the plurality of probes 202. The displacement sensor 210 is configured to measure a displacement of the plurality of probes 202 (e.g., each of the probes 202) in at least one dimension of the fixed coordinate system 112 as the plurality of probes 202 are moved into contact with the indexing feature 104. In one example, the displacement sensor 210 generates displacement data representative of the displacement or movement of the probes 202 and corresponding to the probe positions 204. This displacement data is an example of the probe position data 254 FIG. 24 ) provided to the controller 110.

[0226] Referring to FIGS. 21-23 In one example, the indexing apparatus 100 includes a vehicle 160. The vehicle 160 is configured to support the fixture 102 and move the fixture 102 relative to the operating unit 106. In one example, the vehicle 160 is configured to move the fixture 102, and thus the workpiece 170, to a work location 258 at which the plurality of probes 202 extend into engagement with the indexing feature 104 to perform the positioning and indexing operations described above.

[0227] Referring to FIG. 1 In one example of the indexing apparatus 100, the vehicle 160 includes or takes the form of an automated guided vehicle 162. Referring to FIG. 1 and FIG. 22 In one example of the indexing apparatus 100, the vehicle 160 includes or takes the form of a cart 164. The cart 164 is configured to travel along a track 166 that extends through the operating unit 106.

[0228] In one example, the track 166 is arranged such that the Z coordinate of the fixture 102, and thus the indexing feature 104, is fixed and remains constant as the cart 164 travels along the track 166 to the work location 258. In this example, the positioning operation performed by the plurality of probes 202 only needs to determine the XY coordinates of the indexing feature 104.

[0229] Referring to FIG. 1 and FIG. 21 In another example, the manufacturing system 168 includes the operating unit 106 and the automated machine 128. The automated machine 128 is located in the operating unit 106 and is configured to perform at least one manufacturing operation. The manufacturing system 168 also includes the fixture 102. The fixture 102 is configured to support the workpiece 170 and is movable relative to the operating unit 106. The manufacturing system 168 also includes the indexing feature 104. The indexing feature 104 is fixed relative to the fixture 102. For example, the indexing feature 104 is located on the fixture 102.

[0230] The manufacturing system 168 also includes the plurality of probes 202. The plurality of probes 202 is movable relative to the operating unit 106 and the fixture 102. The plurality of probes 202 is configured to engage the indexing feature 104. The manufacturing system 168 also includes the controller 110 in communication with the plurality of probes 202 and the automated machine 128. The controller 110 is configured to position the fixture 102 relative to the operating unit 106 based on the plurality of probe positions 204 of the plurality of probes 202 engaged with the indexing feature 104. The controller 110 is also configured to index the automated machine 128 relative to the fixture position 118 of the fixture 102.

[0231] Referring to FIG. 1 and FIG. 24 In one example of the manufacturing system 168, the controller 110 is structured to determine a plurality of probe positions 204 of the plurality of probes 202 relative to the reference frame 216, for example in at least one dimension of the fixed coordinate frame 112. The controller 110 is further structured to determine a tool positioning feature position 116 of the tool positioning feature 104 relative to the reference frame 216, for example in at least one dimension of the fixed coordinate frame 112, from the plurality of probe positions 204 of the plurality of probes 202. The controller 110 is further structured to determine a fixed tool position 118 of the fixed tool 102 relative to the reference frame 216 in at least one dimension of the fixed coordinate frame 112 from the tool positioning feature position 116 of the tool positioning feature 104. The controller 110 is further structured to register a digital model 120 representing the fixed tool 102 and the tool positioning feature 104 to the tool positioning feature position 116 of the tool positioning feature 104, and to convert a model position 126 of the digital model 120 registered to the tool positioning feature position 116 to the fixed tool position 118 of the fixed tool 102.

[0232] Referring to FIG. 1 and FIG. 21 In one example of the manufacturing system 168, the fixed tool 102 comprises or takes the form of a mandrel 130 structured to support a composite laminate, and the automated machine 128 comprises or takes the form of an automated fiber placement machine 132.

[0233] Referring to FIG. 21 and FIG. 22 In one example of the manufacturing system 168, the plurality of probes 202 are structured to engage the tool positioning feature 104 when the fixed tool 102 is inside the working envelope 140 of the operational unit 106. In one example of the manufacturing system 168, the tool positioning feature 104 comprises or takes the form of at least one surface 194 of the fixed tool 102. Each of the plurality of probes 202 is moved into contact with the at least one surface 194 along at least one dimension of the fixed coordinate frame 112.

[0234] Referring to FIG. 23 and FIGS. 25-27In one example of the manufacturing system 168, the indexing feature 104 includes at least one interface index 146 located on the surface 194 of the fixed tool 102. Each of the plurality of probes 202 includes a contact index 148 that is movable relative to the at least one interface index 146 and is configured to engage the at least one interface index 146. In one example, the interface index 146 includes an interface structure 206 and the contact index 148 includes a probe head 208 of a corresponding probe of the plurality of probes 202. The probe head 208 is configured to engage the interface structure 206 such that the contact index 148 contacts the interface index 146.

[0235] Referring to FIG. 1 and FIGS. 21-23 In one example, the manufacturing system 168 includes the vehicle 160. The vehicle 160 is configured to support the fixed tool 102 and move the fixed tool 102 relative to the operational unit 106.

[0236] Referring to FIG. 1 and FIG. 21 In one example, the manufacturing system 168 further includes the track 166. The track 166 extends through the operational unit 106. In this example, the vehicle 160 includes or takes the form of a cart 164 that is configured to travel along the track 166.

[0237] Referring to FIG. 28 In one example, the manufacturing system 168 includes a second operational unit 172 and a second automated machine 174. The second automated machine 174 is located in the operational unit 106 and is configured to perform at least one manufacturing operation.

[0238] The manufacturing system 168 further includes a second plurality of probes 212. The second plurality of probes 212 is movable relative to the second operational unit 172 and the fixed tool 102. The second plurality of probes 212 is configured to engage the indexing feature 104. The controller 110 is in communication with the second plurality of probes 212 and the second automated machine 174. The controller 110 is configured to position the fixed tool 102 relative to the second operational unit 172 based on a second plurality of probe positions 214 of the second plurality of probes 212 that are engaged with the indexing feature 104. The controller 110 is further configured to index the second automated machine 174 relative to a second fixed tool position 180 of the fixed tool 102. Once indexed, the second automated machine 174 performs the at least one manufacturing operation on the workpiece 170.

[0239] Referring to FIG. 10 , FIG. 20 and FIG. 28In one example of the manufacturing system 168, the track 166 extends from the operating unit 106 to the second operating unit 172 and through the second operating unit 172. In other words, the track 166 links the operating unit 106 with the second operating unit 172. As shown in FIG. 1, the track 166 is a continuous track that extends from the operating unit 106 to the second operating unit 172. In other examples, the track 166 can include one or more discontinuities (e.g., gaps) between the operating unit 106 and the second operating unit 172. FIG. 10 , FIG. 20 and FIG. 28 In one example, the operating unit 106 and the second operating unit 172 are arranged in a continuous link order. In these examples, the manufacturing system 168 is a continuous flow manufacturing system in which at least a portion of one or more manufacturing operations are performed in each operating unit. Although only two operating units (e.g., the operating unit 106 and the second operating unit 172) are shown by way of example in FIG. 10 , FIG. 20 and FIG. 28 In other examples, the manufacturing system 168 can include any number of operating units.

[0240] In the examples shown in FIG. 29 , FIGS. 1-10 and FIG. 29 As the fixture 102 and the workpiece 170 continuously travel along the manufacturing system 168, the entire fixture 102 and the entire workpiece 170 are located in a corresponding one of the operating unit 106 and the second operating unit 172. In another example, however, the fixture 102 and the workpiece 170 extend between more than one operating unit of the manufacturing system 168. For example, a first portion (or first segment) of the fixture 102 and a first portion (or first segment) of the workpiece 170 are located in the operating unit 106, and a second portion (or second segment) of the fixture 102 and a second portion (or second segment) of the workpiece 170 are located in the second operating unit 172. In this example of the manufacturing system 168, the operating unit 106 and the second operating unit 172 are dependent on one another such that the manufacturing operations performed in the second operating unit 172 build on or add to the manufacturing operations performed in the operating unit 106. This arrangement is particularly advantageous for examples in which the fixture 102 and the workpiece 170 are large, elongated structures. For example, the workpiece 170 can be a spar, a wing segment, or a fuselage segment of an aircraft, and the fixture 102 is a fixture configured to support and securely hold the large workpiece 170.

[0241] In other examples (not shown) of the manufacturing system 168, the operating unit 106 and the second operating unit 172 are positioned separately and independently of one another. In this example, the vehicle 160 (e.g., the automated guided vehicle 162) is configured to move along a predetermined travel path to move the fixture 102 and the workpiece 170 between the different operating units.

[0242] In the examples shown herein, the fixture tool 102 is a rigid body and the indexing feature 104 is coupled to the fixture tool 102. However, in other examples, the fixture tool 102 and the vehicle 160 form a rigid body. For example, the fixture tool 102 and the vehicle 160 can be integrated as a unitary member. In these examples, the position of the indexing feature 104 is also fixed relative to the vehicle 160. For example, the indexing feature 104 can be coupled to the vehicle 160, disposed on the vehicle 160, or otherwise associated with the vehicle 160, rather than the fixture tool 102.

[0243] As described herein, the positioning and indexing operations advantageously enable the fixture tool 102 and the workpiece 170 to be moved to approximate positions within the operational cell 106 relative to the automated machine 128. For example, the instant position of the fixture tool 102 (e.g., the fixture tool position 118) determined by the clamp 108, the sensor 184, or the probe 202 described above becomes the work position 258 at which the automated machine 128 indexes itself. This operation improves the cycle time of the manufacturing operation by eliminating the need for incremental indexing of the automated machine 128 relative to the workpiece 170 and the need to use immovable fixtures to set the workpiece 170 in a particular predetermined position.

[0244] As described herein, the positioning and indexing operations also advantageously enable the subsequent fixture tool 102 and workpiece 170 to be positioned at a moderately different work position within the operational cell 106 and relative to the automated machine 128. In other words, the work position 258 of the fixture tool 102 and the workpiece 170 at which the manufacturing operation is performed does not need to be the same, fixed, and repeatable position for subsequent workpieces 170.

[0245] Although not explicitly shown, in one or more examples of the indexing apparatus 100 and / or the manufacturing system 168, the interface device 220 includes a combination (e.g., two or more) of the clamp 108, the sensor 184, and / or the probe 202. The combination of the clamp 108, the sensor 184, and / or the probe 202 is used to interface with the corresponding indexing feature 104 in order to position the fixture tool 102 and index the fixture tool 102 based on the position of the indexing feature 104.

[0246] FIG. 30 is an example of a flowchart of a manufacturing method 1000. Reference is made generally to FIG. 1 , and in particular to FIGS. 11-20The method 1000 includes a step of securing the workpiece 170 to the securing tool 102 (block 1002). With the workpiece 170 secured to the securing tool 102, the position of the workpiece 170 (workpiece position 262) is fixed and known relative to the securing tool 102. Additionally, the geometry of the workpiece 170 (workpiece geometry 268) is known. According to the method 1000, the securing tool 102 is positioned relative to the operating unit 106 (e.g., relative to the reference frame 216), which in turn positions the workpiece 170 relative to the operating unit 106 (e.g., relative to the reference frame 216).

[0247] The method 1000 includes a step of moving the securing tool 102 relative to the operating unit 106 (block 1004). The method 1000 also includes a step of engaging the indexing feature 104 with the gripper 108 (block 1006). The position of the indexing feature 104 (indexing feature position 116) is fixed and known relative to the securing tool 102. In one example, the indexing feature 104 is coupled to the securing tool 102. The method 1000 also includes a step of positioning the securing tool 102 relative to the operating unit 106 according to the position of the gripper 108 (gripper position 114) with the gripper 108 engaged to the indexing feature 104 (block 1010).

[0248] The method 1000 includes a step of indexing the automated machine 128 relative to the position of the securing tool 102 (securing tool position 118) (block 1016). According to the method 1000, the automated machine 128 is indexed relative to the position of the securing tool 102 (securing tool position 118), which in turn indexes the automated machine 128 relative to the position of the workpiece 170 (workpiece position 262). The method 1000 also includes a step of performing at least one manufacturing operation on the workpiece 170 using the automated machine 128 (block 1018). With the automated machine 128 indexed relative to the position of the securing tool 102 (securing tool position 118), the geometry of the workpiece 170 (workpiece geometry 268) and the position of the workpiece 170 relative to the securing tool 102 (workpiece position 262) are incorporated into and accounted for by a programmed tool path of the automated machine 128 during performance of the manufacturing operation.

[0249] In one example, the method 1000 includes a step of determining a position of the gripper 108 relative to the operating unit 106 (gripper position 114), e.g., in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216 (block 1008). The method 1000 also includes a step of determining a position of the indexing feature 104 relative to the operating unit 106 (indexing feature position 116), e.g., in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216, from the position of the gripper 108 (gripper position 114) (block 1012). The method 1000 also includes a step of determining a position of the fixed tool 102 relative to the operating unit 106 (fixed tool position 118), e.g., in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216, from the position of the indexing feature 104 (indexing feature position 116) (block 1014).

[0250] In one example, the method 1000 includes a step of registering a digital model 120 representing the fixed tool 102 and the indexing feature 104 to the position of the indexing feature 104 (indexing feature position 116). The method 1000 also includes a step of converting a position of the digital model 120 (model position 126) registered to the position of the indexing feature 104 (indexing feature position 116) to a position of the fixed tool 102 (fixed tool position 118). In other words, when the digital model 120 is registered to the position of the indexing feature 104 (indexing feature position 116), the position of the fixed tool 102 (fixed tool position 118) is assumed to be (within a tolerance) the same as the position of the digital model 120 (model position 126).

[0251] In one example, the method 1000 includes a step of moving the fixed tool 102 to a working position 258 (e.g., within the working envelope 140 of the operating unit 106) using the gripper 108, while (e.g., substantially simultaneously with) performing the step of determining the position of the gripper 108 (gripper position 114) (block 1008) and the step of determining the position of the indexing feature 104 (indexing feature position 116) (block 1008).

[0252] In one example, the method 1000 includes a step of engaging the interface indexing 146 of the indexing feature 104 with the contact indexing 148 of the gripper 108, e.g., when performing the step of engaging the indexing feature 104 with the gripper 108 (block 1004). The method 1000 also includes a step of generating gripper position data 238 representing XYZ coordinates of a contact point between the contact indexing 148 and the interface indexing 146.

[0253] In one example, the method 1000 includes a step of clamping the plate 150 of the index feature 104 with the jaw assembly 144 of the clamp 108. The method 1000 also includes a step of engaging the interface index 146 coupled to the plate 150 with the contact index 148 coupled to the jaw assembly 144.

[0254] FIG. 30 is a flowchart of an example of the manufacturing method 2000. Reference is made generally to FIG. 31 and FIG. 1 and specifically to FIGS. 21-28 In one example, the method 3000 includes a step of securing the workpiece 170 to the securing tool 102 (block 2002). With the workpiece 170 secured to the securing tool 102, the position of the workpiece 170 (workpiece position 262) is fixed and known relative to the securing tool 102. Additionally, the geometry of the workpiece 170 (workpiece geometry 268) is known. According to the method 1000, the securing tool 102 is positioned relative to the operating unit 106 (e.g., relative to the reference frame 216), which in turn positions the workpiece 170 relative to the operating unit 106 (e.g., relative to the reference frame 216).

[0255] The method 2000 includes a step of moving the securing tool 102 relative to the operating unit 106 (block 2004). The method 2000 also includes a step of detecting (e.g., visually identifying) the index feature 104 with the sensor 184 (block 2006). The position of the index feature 104 (index feature position 116) is fixed and known relative to the securing tool 102. In one example, the index feature 104 is located on the securing tool 102. The method 2000 also includes a step of positioning the securing tool 102 relative to the operating unit 106 according to the position of the index feature 104 (index feature position 116) detected by the sensor 184 (block 2008).

[0256] The method 2000 also includes a step of indexing the automated machine 128 relative to the position of the fixture tool 102 (fixture tool position 118) (block 2014). According to the method 2000, the automated machine 128 is indexed relative to the position of the fixture tool 102 (fixture tool position 118), which in turn is indexed relative to the position of the workpiece 170 (workpiece position 262). The method 2000 also includes a step of performing at least one manufacturing operation on the workpiece 170 using the automated machine 128 (block 2016). With the automated machine 128 indexed relative to the position of the fixture tool 102 (fixture tool position 118), the geometry of the workpiece 170 (workpiece geometry 268) and the position of the workpiece 170 relative to the fixture tool 102 (workpiece position 262) are incorporated into and accounted for by the programmed tool path of the automated machine 128 during performance of the manufacturing operation.

[0257] In one example, the method 2000 includes a step of determining the position of the indexing feature 104 relative to the operating unit 106 (indexing feature position 116) (block 2010) from the sensor data 186 generated by the sensor 184, e.g., in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216. The method 2000 also includes a step of determining the position of the fixture tool 102 relative to the operating unit 106 (fixture tool position 118) (block 2012) from the position of the indexing feature 104 (indexing feature position 116), e.g., in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216.

[0258] In one example, the method 2000 includes a step of registering the digital model 120 representing the fixture tool 102 and the indexing feature 104 to the position of the indexing feature 104 (indexing feature position 116). The method 2000 also includes a step of converting the position of the digital model 120 (model position 126) registered to the position of the indexing feature 104 (indexing feature position 116) to the position of the fixture tool 102 (fixture tool position 118). In other words, when the digital model 120 is registered to the position of the indexing feature 104 (indexing feature position 116), the position of the fixture tool 102 (fixture tool position 118) is assumed to be (within tolerance) the same as the position of the digital model 120 (model position 126).

[0259] In one example, the method 2000 includes a step of using the sensor 184 to detect (e.g., visually detect) at least one interface structure 192 of the indexing feature 104, the at least one interface structure located on the surface 194 of the fixture tool 102. The method 2000 also includes a step of generating sensor data 186 representing XYZ coordinates of the interface structure 192.

[0260] FIG. 30 is a flowchart of an example of the method 3000. Referring generally to FIG. 32 and FIG. 33 , and specifically to FIG. 34 , the method 3000 includes a step of securing the workpiece 170 to the securing tool 102 (block 3002). With the workpiece 170 secured to the securing tool 102, the position of the workpiece 170 (workpiece position 262) is fixed and known relative to the securing tool 102. Additionally, the geometry of the workpiece 170 (workpiece geometry 268) is known. According to the method 1000, the securing tool 102 is positioned relative to the operating unit 106 (e.g., relative to the reference frame 216), which in turn positions the workpiece 170 relative to the operating unit 106 (e.g., relative to the reference frame 216).

[0261] The method 3000 includes a step of moving the securing tool 102 relative to the operating unit 106 (block 3004). The method 3000 also includes a step of engaging the indexing feature 104 with the plurality of probes 202 (block 3006). The position of the indexing feature 104 (indexing feature position 116) is fixed and known relative to the securing tool 102. In one example, the indexing feature 104 is coupled to the securing tool 102. The method 3000 also includes a step of positioning the securing tool 102 relative to the operating unit 106 according to the positions of the plurality of probes 202 (plurality of probe positions 204) with the plurality of probes 202 engaged to the indexing feature 104 (block 3010).

[0262] The method 3000 also includes a step of indexing the automated machine 128 relative to the position of the securing tool 102 (securing tool position 118) (block 3016). According to the method 3000, the automated machine 128 is indexed relative to the position of the securing tool 102 (securing tool position 118), which in turn indexes the automated machine 128 relative to the position of the workpiece 170 (workpiece position 262). The method 3000 also includes a step of performing at least one manufacturing operation on the workpiece 170 using the automated machine 128 (block 3018). With the automated machine 128 indexed relative to the position of the securing tool 102 (securing tool position 118), the geometry of the workpiece 170 (workpiece geometry 268) and the position of the workpiece 170 relative to the securing tool 102 (workpiece position 262) are incorporated into and accounted for by the programmed tool path of the automated machine 128 during performance of the manufacturing operation.

[0263] In one example, the method 3000 includes a step of determining a position of the plurality of probes 202 relative to the operating unit 106 (the plurality of probe positions 204) (block 3008), e.g., in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216. The method 3000 also includes a step of determining a position of the index feature 104 relative to the operating unit 106 (the index feature position 116) (block 3012) from the positions of the plurality of probes 202 (the plurality of probe positions 204), e.g., in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216. The method 3000 also includes a step of determining a position of the fixed tool 102 relative to the operating unit 106 (the fixed tool position 118) (block 3014) from the position of the index feature 104 (the index feature position 116), e.g., in at least one dimension of the fixed coordinate system 112 relative to the reference frame 216.

[0264] In one example, the method 3000 includes a step of registering a digital model 120 representing the fixed tool 102 and the index feature 104 to the position of the index feature 104 (the index feature position 116). The method 3000 includes a step of converting a position of the digital model 120 (the model position 126) registered to the position of the index feature 104 (the index feature position 116) to a position of the fixed tool 102 (the fixed tool position 118). In other words, when the digital model 120 is registered to the position of the index feature 104 (the index feature position 116), the position of the fixed tool 102 (the fixed tool position 118) is assumed to be (within a tolerance) the same as the position of the digital model 120 (the model position 126).

[0265] In one example, the method 3000 includes a step of moving the fixed tool 102 to a work position 258 (e.g., within the work envelope 140 of the operating unit 106). The method 3000 also includes a step of moving the plurality of probes 202 into contact with the index feature 104 along at least one dimension of the fixed coordinate system 112.

[0266] In one example, the method 3000 includes a step of engaging the interface index 146 of the index feature 104 with the contact index 148 of each of the plurality of probes 202, e.g., when performing the step of engaging the index feature 104 with the plurality of probes 202 (block 3006). The method 3000 also includes a step of generating probe position data 254 representing XYZ coordinates of a point of contact between the contact index 148 and the interface index 146.

[0267] In one example, the method 3000 includes a step of engaging the interface structure 206 of the index feature 104 with the probe head 208 of the probe 202. The method 1000 also includes a step of engaging the interface index 146 formed by the interface structure 206 with the contact index 148 formed by the probe head 208.

[0268] FIG. 33 An example of the controller 110 is schematically illustrated, and more particularly, a computing device 224 of the controller 110 is illustrated. The controller 110 includes any suitable programmable controller configured to control one or more manufacturing processes and perform one or more computing or data processing operations. Operations performed by various examples of the disclosed indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000, and / or portions thereof are implemented under computer control provided by the controller 110. The controller 110 can be any number of programmable controllers and / or include any number of computing devices 224.

[0269] The computing device 224 is an example of a data processing system for performing one or more functions provided by the disclosed indexing apparatus 100 and manufacturing system 168 or implementing one or more operational steps of the disclosed methods 1000, 2000, 3000. The computing device 224 includes a communication bus 602 that provides communication among a processor unit 604, a memory 606, a persistent storage 608, a communication unit 610, an input / output (“I / O”) unit 612, and a display 614.

[0270] The communication bus 602 includes one or more buses, such as a system bus or an input / output bus. The communication bus 602 is implemented using any suitable type of architecture that provides for the transfer of data between different components or devices attached to the bus system.

[0271] The processor unit 604 is any suitably programmed computer processor configured to execute instructions, such as software instructions loaded onto the memory 606. The processor unit 604 can be any number of processors, multi-processor cores, microprocessors, or any other type of processor, depending on the implementation of the controller 110.

[0272] The memory 606 and the persistent storage 608 are examples of storage devices 616. The storage devices 616 are any hardware able to store information, including but not limited to data, program code in functional form, and / or other suitable information, either temporarily or permanently. For example, the memory 606 can be a random access memory or any other suitable volatile or non-volatile storage device. The memory 606 can also be referred to as a non-transitory computer readable storage medium.

[0273] The persistent storage 608 can take various forms depending on the implementation. The persistent storage 608 can include one or more components or devices. For example, the persistent storage 608 can be a hard disk drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination thereof.

[0274] The communication unit 610 provides for communication with other data processing systems or devices, for example, over wired and / or wireless communication links. The communication unit 610 can include one or more devices for sending and receiving data, such as a network interface card, a modem, or a network adapter.

[0275] The input / output unit 612 enables input and output of data with other devices connected to the controller 110. For example, the input / output unit 612 can provide a connection for input through a keyboard, mouse, and / or some other suitable input device. Further, the input / output unit 612 can send output to the display 614 to display information.

[0276] Instructions for the operating system, applications, and / or programs can be located in the storage 616, which is in communication with the processor unit 604 through the communication bus 602. In one example, the computer- implemented instructions are functional form on the persistent storage 608. The instructions are loaded into the memory 606 for execution by the processor unit 604. One or more of the processes and / or operations described herein are performed by the processor unit 604 using the computer- implemented instructions.

[0277] The computer-implemented instructions can be referred to as program code, computer-usable program code, or computer-readable program code that is readable and executable by at least one processor of the processor unit 604. The program code can be implemented on different physical or computer-readable storage media, such as the memory 606 or the persistent storage 608.

[0278] In one example, the program code 618 is in functional form on the computer- readable medium 620, which is selectively removable and can be loaded or transferred to the computing device 224 for execution by the processor unit 604. In one example, the program code 618 and the computer-readable medium 620 form a computer program product 622. The computer-readable medium 620 can be a computer-readable storage medium 624 or a computer-readable signal medium 626.

[0279] The computer readable storage medium 624 can include, but is not limited to, an optical disk or a magnetic disk which is inserted or placed into a drive or other device that is part of the permanent storage 608 in order to transfer into or read from the storage device (e.g., a hard disk drive) that is part of the permanent storage 608. The computer readable storage medium 624 can take the form of a permanent storage device, such as a hard drive, thumb drive, networked device, cloud, flash memory, optical disk, magnetic disk, etc. The computer readable storage medium 624 is connected or otherwise accessed by the computing device 224.

[0280] In one example, the operations performed by various examples of the disclosed indexing apparatus 100 and manufacturing system 168, and the operational steps implemented by various examples of the disclosed methods 1000, 2000, 3000 and / or portions thereof, can be implemented as or utilize a computer program product that includes a non-transitory computer readable storage medium and computer control logic stored on the non-transitory computer readable storage medium.

[0281] Accordingly, various implementations of the devices, systems and methods described herein can be realized in digital electronic circuitry, integrated circuitry, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations can include implementation in one or more computer programs that are executable and / or interpretable on a programmable system including at least one programmable processor, which can be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.

[0282] Computer programs (also known as programs, software, software applications or code) include machine instructions for a programmable processor, and can be implemented in a high-level procedural and / or object-oriented programming language, and / or in assembly / machine language. As used herein, the terms "machine-readable medium" "computer-readable medium" refers to any computer program product, apparatus and / or device (e.g., magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used to provide machine instructions and / or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term "machine-readable signal" refers to any signal used to provide machine instructions and / or data to a programmable processor.

[0283] While one or more of the examples described herein relate to fully automated manufacturing systems and operations, in one or more other examples, the indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 are used with partially automated manufacturing systems and operations or manual manufacturing systems and operations, where the fixture tool 102 is positioned relative to a work station and the manufacturing machine is indexed relative to the fixture tool 102 in order to perform one or more manufacturing operations on the workpiece 170. Such manufacturing operations include subtractive manufacturing operations, additive manufacturing operations, and assembly operations performed on the workpiece 170. In one example, the manufacturing operations are performed on a post-cured composite material or other material. In another example, the manufacturing operations are performed on a pre-cured composite material, such as a composite layup operation and a composite lamination operation.

[0284] Referring now to FIG. 34 and FIG. 34 , examples of the indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 can be used in the context of an aircraft manufacturing and service method 1100, as shown in the flow diagram and aircraft 1200, as shown schematically in FIG. 33 FIG. 33

[0285] FIG. 33 is an illustrative example of an aircraft 1200. The aircraft 1200 includes an airframe 1202 and a plurality of high-level systems 1204. Examples of high-level systems 1204 include one or more of a propulsion system 1208, an electrical system 1210, a hydraulic system 1212, and an environmental system 1214. In other examples, the aircraft 1200 can include any number of other types of systems, such as a communication system, a guidance system, etc. The workpiece 170 can be any of a structure, assembly, subassembly, component, and portion of the airframe 1202 or interior finish 1206. For example, the workpiece 170 can be any of an aircraft spar, a wing section, an airframe section, an interior panel, an exterior skin panel, etc.

[0286] As shown in FIG. 1 , during pre-production, the method 1100 can include specification and design of the aircraft 1200 (block 1102) and material procurement (block 1104). During production of the aircraft 1200, component and subassembly manufacturing (block 1106) and system integration (block 1108) of the aircraft 1200 can take place. Thereafter, the aircraft 1200 can go through certification and delivery (block 1110) in order to be placed in service (block 1112). Routine maintenance and service (block 1114) can include modification, reconfiguration, refurbishment, etc. of one or more systems of the aircraft 1200.

[0287] FIG. 34 ​​Each of the processes of method 1100 shown in FIG. 11 can be performed or implemented with hardware, software, firmware or any combination thereof, as desired for a given set of design criteria, as will be apparent to those of skill in the art in light of the teachings herein. For example, some processes can be performed or implemented by an application-specific machine, or other machine, as desired for a given set of design criteria. Any of the processes of method 1100 shown in FIG. 11 can be employed during any one or more of the stages of manufacturing and servicing method 1100 shown in FIG. 11. In one example, implementations of the disclosed indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 can form part of component and subassembly manufacturing (block 1106) and / or system integration (block 1108). For example, assembling an aircraft 1200, fuselage 1202, and / or components thereof using implementations of the disclosed indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 can correspond to component and subassembly manufacturing (block 1106), and can be made in a manner similar to that of components or subassemblies made while the aircraft 1200 is in service (block 1112). Further, implementations of the disclosed indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 can be utilized during system integration (block 1108) as well as certification and delivery (block 1110). Similarly, implementations of the disclosed indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 can be utilized when the aircraft 1200 is in service (block 1112), for example, and during maintenance and service (block 1114).

[0288] The examples of the indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 shown and described herein can be employed in FIG. 1 Any one or more stages of the manufacturing and servicing method 1100 shown in the flowcharts can be employed. In one example, implementations of the disclosed indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 can form part of component and subassembly manufacturing (block 1106) and / or system integration (block 1108). For example, assembling an aircraft 1200, fuselage 1202, and / or components thereof using implementations of the disclosed indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 can correspond to component and subassembly manufacturing (block 1106), and can be made in a manner similar to that of components or subassemblies made while the aircraft 1200 is in service (block 1112). Further, implementations of the disclosed indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 can be utilized during system integration (block 1108) as well as certification and delivery (block 1110). Similarly, implementations of the disclosed indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 can be utilized when the aircraft 1200 is in service (block 1112), for example, and during maintenance and service (block 1114).

[0289] Referring to FIG. 34 and FIG. 1 , methods of manufacturing a portion of an aircraft 1200 FIG. 34 using the indexing apparatus 100 FIG. 29 and methods of manufacturing a portion of an aircraft 1200 FIG. 34 using the manufacturing system 168 FIG. 29 are also disclosed. Referring to FIG. 30 and FIG. 34 , portions of an aircraft 1200 assembled according to the method 1000 FIG. 30 are also disclosed. Referring to FIG. 31 and FIG. 34 , portions of an aircraft 1200 assembled according to the method 2000 FIG. 31 are also disclosed. Referring to FIG. 1 andFIG. 7 Also disclosed is a portion of an aircraft 1200 assembled according to the method 3000 FIG. 16 ) The portion of the aircraft 1200 includes one or more of structures, components, parts, assemblies, and subassemblies of any of the fuselage 1202, the interior 1206, and the high-level systems 1204.

[0290] As used herein, a system, device, apparatus, structure, article, element, component, or hardware that is “configured to” perform a particular function is actually capable of performing the particular function without further modification, rather than merely having the potential to perform the particular function after a further modification is made. In other words, a system, device, apparatus, structure, article, element, component, or hardware that is “configured to” perform a particular function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the particular function without a further modification. As used herein, “configured to” denotes an existing characteristic that enables a system, device, structure, article, element, component, or hardware to perform a specified function without a further modification. For purposes of the present disclosure, a system, device, apparatus, structure, article, element, component, or hardware that is described as being “configured to” perform a particular function can additionally or alternatively be described as being “adapted to” and / or “operative to” perform that function.

[0291] For purposes of the present disclosure, the terms “coupled,” “connected,” and similar terms, mean two or more elements are in some way linked or associated with each other— whether directly or indirectly— in connection with one another. In various examples, the elements can be linked or associated with each other in a direct line or in a non-direct line. As an example, element A can be directly associated with element B. As another example, element A can be indirectly associated with element B, e.g., via another element C. It is understood that not all associations between various disclosed elements are necessarily represented. Thus, there can be associations other than those shown in the figures.

[0292] As used herein, the terms “about” and “approximately” mean or refer to a condition that is close, but not necessarily exact, to a stated condition. As an example, the terms “about” and “approximately” refer to a condition that is within an acceptable predetermined tolerance or precision. For example, the terms “about” and “approximately” refer to a condition that is within 10% of the stated condition. However, the terms “about” and “approximately” do not exclude a condition that is exactly the stated condition.

[0293] In the above-mentioned FIG. 25 , FIG. 32 , FIG. 34 , FIGS. 1-29 , FIG. 32 and FIG. 34In the description provided herein, blocks can represent modules, segments, or portions of code which include one or more FIGS. 1-29 , FIG. 32 and FIG. 34 elements described and illustrated in the examples of ​ , ​ and ​ above need not be included in every example, and not all examples described herein must include every element described or illustrated in the above examples. The above-mentioned examples of

[0294] In the description provided herein, blocks can represent operations, steps and / or portions of codes which include one or more Figures 29 to 31 and Figure 33 operations, and connections between blocks do not imply any particular order or dependency between operations or portions thereof. It will be understood that not all dependencies between various disclosed operations need be represented. Figures 29 to 31 and Figure 33 The additional disclosures describing operations of the disclosed methods described herein should not be interpreted as necessarily determining the order in which the operations are performed. Rather, although an illustrative order is indicated, it will be understood that the order of the operations can be modified as appropriate. Thus, the illustrated operations can be modified, added and / or omitted, and certain operations can be performed in different orders or simultaneously. Additionally, those skilled in the art will understand that not all of the described operations need be performed.

[0295] Furthermore, reference to features, advantages, or similar language in the specification to

[0296] The described features, advantages, and properties of the example can be combined in any suitable manner in one or more further examples. Those skilled in the relevant art will recognize that the examples described herein can be practiced with or without the specific features or advantages of a particular example. In other instances, additional features and advantages can be recognized in certain examples that can not be present in all examples. Further, while various examples of the indexing apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 have been illustrated and described, modifications can be made by those skilled in the art upon reading the specification after the application has been disclosed.

[0297] Further, the present disclosure includes examples in accordance with the following clauses:

[0298] Clause:

[0299] 1. An indexing apparatus, comprising:

[0300] a stationary tool movable relative to an operating unit;

[0301] an indexing feature fixed relative to the stationary tool;

[0302] a gripper configured to engage the indexing feature; and

[0303] a controller in communication with the gripper, wherein the controller is configured to position the stationary tool relative to the operating unit as a function of a gripper position of the gripper engaged with the indexing feature.

[0304] 2. The apparatus of clause 1, wherein the controller is further configured to:

[0305] determine the gripper position of the gripper in at least one dimension of a fixed coordinate system;

[0306] determine an indexing feature position of the indexing feature in the at least one dimension of the fixed coordinate system as a function of the gripper position of the gripper; and

[0307] determine a stationary tool position of the stationary tool in the at least one dimension of the fixed coordinate system as a function of the indexing feature position of the indexing feature.

[0308] 3. The apparatus of clause 2, wherein the controller is further configured to:

[0309] register a digital model representing the stationary tool and the indexing feature to the indexing feature position of the indexing feature; and

[0310] converting a model position of the digital model that is to be registered to the location of the index feature to the fixture position of the fixture.

[0311] 4. The apparatus of clause 2 or 3, wherein the controller is further configured to index the automated machine relative to the fixture position of the fixture.

[0312] 5. The apparatus of clause 4, wherein:

[0313] the fixture comprises a mandrel configured to support a pre-cured composite laminate; and

[0314] the automated machine is configured to perform a pre-cure manufacturing operation on the pre-cured composite laminate.

[0315] 6. The apparatus of clause 4 or 5, wherein:

[0316] the fixture comprises a holding feature configured to hold a post-cured composite structure; and

[0317] the automated machine is configured to perform a post-cure manufacturing operation on the post-cured composite structure.

[0318] 7. The apparatus of clause 4, 5, or 6, wherein:

[0319] the gripper is coupled to the automated machine; and

[0320] the automated machine is configured to move the gripper relative to the fixture 102 in at least one dimension of the fixed coordinate system.

[0321] 8. The apparatus of any of the preceding clauses, further comprising a drive assembly coupled to the gripper and configured to move the gripper relative to the fixture.

[0322] 9. The apparatus of clause 8, wherein the gripper is configured to move the fixture inside a working envelope of the operating cell.

[0323] 10. The apparatus of any of the preceding clauses, wherein:

[0324] the indexing feature comprises:

[0325] a plate extending from the fixture; and

[0326] an interface index on the plate; and

[0327] the gripper comprises:

[0328] a jaw assembly configured to clamp the panel; and

[0329] a contact index coupled to the jaw assembly and configured to engage the interface index.

[0330] 11. A method of manufacturing a portion of an aircraft using the apparatus of any of the preceding clauses.

[0331] 12. A manufacturing system, preferably comprising the indexing apparatus of any of clauses 1-10, comprising:

[0332] an automated machine located in an operating cell and configured to perform at least one manufacturing operation;

[0333] a stationary tool configured to support a workpiece and movable relative to the operating cell;

[0334] an indexing feature fixed relative to the stationary tool;

[0335] a gripper configured to engage the indexing feature; and

[0336] a controller in communication with the gripper and the automated machine; and wherein:

[0337] the controller is configured to position the stationary tool relative to the operating cell as a function of a gripper position of the gripper engaged with the indexing feature; and

[0338] the controller is further configured to index the automated machine relative to a stationary tool position of the stationary tool.

[0339] 13. The system of clause 12, wherein the controller is further configured to:

[0340] determine the gripper position of the gripper in at least one dimension of a fixed coordinate system;

[0341] determine an indexing feature position of the indexing feature in the at least one dimension of the fixed coordinate system as a function of the gripper position of the gripper; and

[0342] determine a stationary tool position of the stationary tool in the at least one dimension of the fixed coordinate system as a function of the indexing feature position of the indexing feature.

[0343] 14. The system of clause 13, wherein the controller is further configured to:

[0344] registering a digital model representing the fixture tool and the index feature to the index feature location of the index feature; and

[0345] converting a model location of the digital model being registered to the index feature location to the fixture tool location of the fixture tool.

[0346] 15. The system of any of clauses 12-14, wherein:

[0347] the fixture tool comprises a mandrel configured to support a composite laminate; and

[0348] the automated machine comprises an automated fiber placement machine.

[0349] 16. The system of any of clauses 12-15, wherein:

[0350] the gripper is coupled to the automated machine; and

[0351] the automated machine is configured to move the gripper relative to the fixture tool.

[0352] 17. The system of any of clauses 12-16, wherein:

[0353] the index feature comprises at least one interface index; and

[0354] the gripper comprises at least one contact index configured to engage at least one interface index.

[0355] 18. The system of any of clauses 12-17, further comprising a vehicle configured to support the fixture tool and move the fixture tool relative to the operations unit, and wherein the vehicle comprises one of an automated guided vehicle and a cart configured to travel along a track extending through the operations unit.

[0356] 19. The system of any of clauses 12-18, further comprising:

[0357] a second operations unit;

[0358] a second automated machine located in the second operations unit and configured to perform at least one manufacturing operation; and

[0359] a second gripper configured to engage the index feature; and wherein:

[0360] the controller is in communication with the second gripper and the second automated machine;

[0361] the controller is configured to position the fixed tool relative to the second operating unit according to a second gripper position of the second gripper engaged with the indexing feature; and

[0362] the controller is further configured to index the second automated machine relative to a second fixed tool position of the fixed tool.

[0363] 20. A method of manufacturing a portion of an aircraft using the system of any one of clauses 11 to 19.

[0364] 21. A method of manufacturing, the method comprising:

[0365] moving a fixed tool relative to an operating unit;

[0366] engaging an indexing feature with a gripper;

[0367] positioning the fixed tool relative to the operating unit according to a gripper position of the gripper engaged with the indexing feature; and

[0368] indexing an automated machine relative to a fixed tool position of the fixed tool.

[0369] 22. The method of clause 21, further comprising:

[0370] determining the gripper position of the gripper in at least one dimension of a fixed coordinate system;

[0371] determining an indexing feature position of the indexing feature in the at least one dimension of the fixed coordinate system according to the gripper position of the gripper; and

[0372] determining the fixed tool position of the fixed tool in the at least one dimension of the fixed coordinate system according to the indexing feature position of the indexing feature.

[0373] 23. The method of clause 21 or 22, further comprising:

[0374] gripping the indexing feature with a gripper head of the gripper; and

[0375] engaging at least one interface indexing of the indexing feature with at least one contact indexing coupled to the gripper head.

[0376] 24. A portion of an aircraft assembled according to the method of any one of clauses 20 to 23.

Claims

1. An indexing apparatus (100), comprising: a fixture (102) configured to support a workpiece (170) and movable relative to an operating unit (106); an indexing feature (104) fixed relative to the fixture (102); a gripper (108) configured to engage the indexing feature; and a controller (110) in electrical and / or data communication with the gripper (108), wherein: the controller (110) is configured to determine a gripper position (114) of the gripper (108) relative to the operating unit (106); with the gripper (108) engaged with the indexing feature (104), the gripper (108) is configured to move the fixture (102) in the operating unit (106); and with the gripper (108) engaged with the indexing feature (104), the controller (110) is further configured to determine a fixture position (118) of the fixture (102) relative to the operating unit (106) based on the gripper position (114) of the gripper (108).

2. The device (100) according to claim 1, wherein the controller (110) is further configured to: determine the gripper position (114) of the gripper (108) in at least one dimension of a fixed coordinate system (112); determine an indexing feature position (116) of the indexing feature (104) in the at least one dimension of the fixed coordinate system (112) from the gripper position (114) of the gripper (108); and determine a fixture position (118) of the fixture (102) in the at least one dimension of the fixed coordinate system from the indexing feature position (116) of the indexing feature (104).

3. The apparatus of claim 2, wherein, the controller (110) is configured to load a digital model (120) representing a geometry of the indexing feature (104) and the fixture (102), wherein the controller is further configured to determine the fixture position (118) and / or a workpiece position (262) representing the workpiece position (170) based on the determined indexing feature position (116) and the loaded digital model (120).

4. The device (100) according to claim 2 or 3, wherein the controller (110) is further configured to: register a digital model (120) representing the fixture (102) and the indexing feature (104) to the indexing feature position (116) of the indexing feature (104); and convert a model position (126) of the digital model (120) registered to the indexing feature position to the fixture position (118) of the fixture (102).

5. The device (100) according to claim 2 or 3, wherein the controller (110) is further configured to index an automated machine (128) relative to the fixture position (118) of the fixture (102).

6. The apparatus (100) of claim 5, wherein: the gripper (108) is coupled to the automated machine (128); and the automated machine (128) is configured to move the gripper (108) relative to the fixed tool (102) in at least one dimension of the fixed coordinate system.

7. The apparatus of any of claims 1-3, further comprising a drive assembly (138) coupled to the gripper (108) and configured to move the gripper (108) relative to the fixed tool.

8. The apparatus of any of claims 1-3, wherein: the indexing feature comprises: a plate extending from the fixed tool; and an interface index located on the plate; and the gripper comprises: a jaw assembly configured to grip the plate; and a contact index coupled to the jaw assembly and configured to engage the interface index.

9. The apparatus of claim 3, wherein, the digital model (120) also represents a geometry of the workpiece (170).

10. The apparatus (100) of claim 5, wherein, the fixed tool (102) comprises a mandrel (130) configured to support a composite layup; and the automated machine (128) is configured to perform a pre-cure manufacturing operation on the composite layup.

11. The device (100) according to claim 10, wherein the mandrel (130) is configured to support a pre-cured composite layup.

12. The apparatus (100) of claim 5, wherein, the fixed tool (102) comprises a holding feature (260) configured to secure a post-cured composite structure; and the automated machine (128) is configured to perform a post-cure manufacturing operation on the post-cured composite structure.

13. The apparatus of claim 7, wherein, the gripper (108) is configured to move the fixed tool inside a working envelope of the operation cell (106).

14. A manufacturing system, comprising: an automated machine (128) located in an operation cell (106) and configured to perform at least one manufacturing operation; an indexing apparatus (100) according to any of the preceding claims; wherein the controller (110) is further configured to index the automated machine (128) relative to a fixed tool position (118) of the fixed tool (102).

15. The system of claim 14, wherein: the fixed tool (102) comprises a mandrel (130) configured to support a composite layup; and the automated machine (128) comprises an automated fiber placement machine (132).

16. The system according to claim 14 or 15, further comprising a vehicle (160) configured to support the fixing tool (102) and to move the fixing tool (102) relative to the operating unit, and wherein the vehicle (160) comprises one of an automated guided cart and a cart (164) configured to travel along a track (166) extending through the operation cell.

17. The system of claim 14 or 15, further comprising: a second operation cell (172); a second automated machine (174) located in the second operating unit and configured to perform at least one manufacturing operation; and a second gripper (176) configured to engage the indexing feature; and wherein: the controller (110) is in electrical and / or data communication with the second gripper and the second automated machine; the controller (110) is configured to position the stationary tool relative to the second operating unit in accordance with a second gripper position (178) of the second gripper engaged with the indexing feature; and the controller (110) is further configured to index the second automated machine relative to a second stationary tool position of the stationary tool.

18. A manufacturing method, the method comprising: moving a stationary tool (102) relative to an operating unit (106); engaging an indexing feature (104) with a gripper (108); moving the stationary tool (102) in the operating unit (106) using the gripper (108) with the gripper (108) engaged with the indexing feature (104); determining a gripper position (114) of the gripper (108) engaged with the indexing feature; and determining a stationary tool position (118) of the stationary tool (102) relative to the operating unit (106) in accordance with the gripper position (114) of the gripper (108); and indexing an automated machine (128) relative to the stationary tool (102) using the stationary tool position (118).

19. The method of claim 18, the method further comprising: determining the gripper position (114) of the gripper (108) in at least one dimension of a fixed coordinate system (112); determining an indexing feature position (116) of the indexing feature in the at least one dimension of the fixed coordinate system in accordance with the gripper position (114) of the gripper (108); and determining the stationary tool position in the at least one dimension of the fixed coordinate system of the stationary tool in accordance with the indexing feature position of the indexing feature, and / or, the method further comprising: loading a digital model (120) representing a geometry of the indexing feature (104) and the stationary tool (102); and determining the stationary tool position (118) and / or a workpiece position (262) representing a workpiece (170) based on the determined indexing feature position (116) and the loaded digital model (120).

20. The method of claim 18 or 19, the method further comprising: gripping the indexing feature (104) with a gripping head (232) of the gripper (108); and engaging at least one interface index (146) of the indexing feature (104) with at least one contact index coupled to the gripping head (232).

21. The method of claim 19, wherein, The digital model (120) also represents a geometry of the workpiece (170).

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