Processing system for manufacturing a part and method thereof

Abstract

To provide a processing system for manufacturing a component.SOLUTION: A processing system for manufacturing a part includes a workpiece having a working surface and an end effector tool. The end effector tool includes a fixture and a set of first processing tools attached to the fixture in a predetermined pattern. The first processing tool is configured to perform an operation on the work surface. The processing system further includes a controller in communication with the end effector tool. The controller is configured to control movement of the end effector tool to position the first processing tool relative to the work surface such that the predetermined pattern is aligned at a predetermined position relative to the work surface. The controller is also configured to control operation of the first processing tool such that the first processing tool performs the operation on the work surface to form a first processing region at the predetermined location of the work surface.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a processing system for manufacturing a part and a method for manufacturing a part. [Background technology]

[0002] Manufacturing processes are used to prepare various workpieces. For example, some workpieces require drilling, deburring, cutting, etc. These manufacturing processes may be automated using machines. However, machines may only be able to drill one hole at a time. Additionally, the size of the workpiece and the size of the machine may limit the number of machines that can be used to drill holes to prepare the workpiece. Summary of the Invention

[0003] It is therefore desirable to develop processing systems and methods that improve manufacturing processes, and other advantages are described herein.

[0004] The present disclosure provides a processing system for manufacturing a part. The processing system includes a workpiece having a work surface and an end effector tool. The end effector tool includes a fixture and a set of first processing tools attached to the fixture in a predetermined pattern. The first processing tools are configured to perform an operation on the work surface. The processing system further includes a controller in communication with the end effector tool. The controller includes a processor configured to execute instructions from a memory, whereby the controller controls movement of the end effector tool to position the first processing tool relative to the work surface so that the predetermined pattern is aligned at a predetermined position relative to the work surface. The controller is also configured to control operation of the first processing tool, whereby the first processing tool performs the operation on the work surface and forms a first processing area at the predetermined position on the work surface.

[0005] The present disclosure further provides a probe assembly for measuring characteristics of a hole in a workpiece, the probe assembly including a probe insertable into a hole in the workpiece to measure the characteristics of the hole, the probe assembly further including a self-aligning compliance assembly connected to the probe, which enables the probe to flexibly conform to the workpiece and accommodate one or more workpiece tolerances when the probe is inserted into the hole.

[0006] The present disclosure further provides a method for manufacturing an aircraft part. A workpiece having a work surface is provided. An end effector tool is selected to perform an operation on the work surface. The end effector tool includes a fixture and a set of first processing tools attached to the fixture in a predetermined pattern. The first processing tools are configured to perform the operation on the work surface. Movement of the end effector tool is controlled via a controller to position the first processing tool relative to the work surface, thereby aligning the predetermined pattern at a predetermined position relative to the work surface. Operation of the first processing tool is controlled via the controller, thereby causing the first processing tool to perform the operation on the work surface and form a first processing area at the predetermined position on the work surface.

[0007] The detailed description and drawings are provided to aid in and explain the present disclosure, the scope of which is defined solely by the claims. Although certain best modes and alternative configurations for carrying out the claimed subject matter have been described in detail, various alternative designs and configurations exist for carrying out the present disclosure as defined by the appended claims. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a schematic diagram illustrating a machine supporting an end effector tool having multiple processing tools and controlling the processing tools. [Figure 2] FIG. 1 is a schematic diagram showing machine-controllable processing tools, a vacuum assembly, and position sensors. [Figure 3] FIG. 1 is a schematic perspective view showing the underside of an end effector tool. [Figure 4] FIG. 1 is a schematic perspective view showing the top side of an end effector tool having a set of first processing tools and a set of second processing tools supported by a fixture. [Figure 5] FIG. 5 is a schematic bottom view of the end effector tool of FIG. 4. [Figure 6] 1 is a schematic perspective view showing the top side of an end effector tool having a set of processing tools in a first configuration. FIG. [Figure 7] FIG. 7 is a schematic perspective view of one of the processing tools of FIG. 6. [Figure 8A] 8 is a schematic side view of the processing tool of FIG. 7. [Figure 8B] 8B is a schematic side view showing the processing tool of FIG. 8A moving the clamp toward the workpiece. [Figure 8C] 8C is a schematic side view showing the processing tool of FIG. 8B moving the drill towards the workpiece. [Figure 8D] 8D is a schematic side view showing the processing tool of FIG. 8C retracting the clamp and drill from the workpiece. [Figure 9A] 8 is a schematic side view of a self-aligning compliance assembly of the processing tool of FIG. 7. [Figure 9B] FIG. 9B is a schematic side view of the self-aligning compliance assembly of the processing tool of FIG. 9A, illustrating the flexibility of the drill. [Figure 10] FIG. 10 is a schematic perspective view showing the upper side of an end effector tool having a set of processing tools in a second configuration. [Figure 11] FIG. 11 is a schematic perspective view of one of the processing tools of FIG. 10. [Figure 12A] 12 is a schematic partial cross-sectional view showing the processing tool of FIG. 11 moving toward the workpiece. [Figure 12B]12B is a schematic partial cross-sectional view showing the processing tool of FIG. 12A discharging fluid as it retracts from the workpiece. FIG. [Figure 13] 12 is a schematic partial cross-sectional view of a self-aligning compliance assembly of the processing tool of FIG. 11. [Figure 14A] 12 is a schematic partial cross-sectional view of the processing tool of FIG. 11 showing a self-aligning compliance assembly before compliance is exerted. [Figure 14B] 14B is a schematic partial cross-sectional view illustrating the flexibility of a self-aligning compliance assembly of the processing tool of FIG. 14A. [Figure 15A] 12 is a schematic partial cross-sectional view showing the processing tool of FIG. 11 moving the measuring device toward the workpiece. [Figure 15B] 15B is a schematic partial cross-sectional view of the processing tool of FIG. 15A illustrating the flexibility of the probe of the measuring device relative to the workpiece prior to attachment of the housing of the measuring device to the workpiece; [Figure 16] 12 is a schematic side view of the processing tool of FIG. 11. [Figure 17] 1 is a flowchart illustrating a general example of a method for manufacturing a part. [Figure 18A] 1 is a first portion of a flowchart illustrating an example of a method for manufacturing a part. [Figure 18B] 18B is a second part of the flowchart of FIG. 18A. DETAILED DESCRIPTION OF THE INVENTION

[0009] The present disclosure is open to modifications and alternative forms, representative configurations of which are illustrated in the drawings and described in detail below. The inventive aspects of the present disclosure are not limited to the disclosed configurations. Rather, the present disclosure is intended to cover modifications, equivalents, combinations, and alternatives falling within the scope of the present disclosure as defined by the appended claims.

[0010] Those skilled in the art will appreciate that all directional references (e.g., "upper," "lower," "up," "upper," "lower," "top," "bottom," "left," "right," "vertical," "horizontal," etc.) are used to aid the reader in describing the drawings and are not intended to impose limitations (e.g., on location, orientation, or use) on the scope of the present disclosure, which is defined by the appended claims. Furthermore, terms such as "first," "second," and "third" may be used to describe separate components. Such terms may include the specific terms discussed above, derivatives thereof, and terms of similar meaning. Furthermore, the term "substantially" may refer to slight inaccuracies or variations in conditions, amounts, values, or dimensions, some of which may occur within manufacturing variations or tolerances.

[0011] As used herein, the use of the singular in an element or step does not necessarily exclude a plurality of elements or steps. Furthermore, reference to "a component" should not be interpreted as excluding the existence of additional components that include the recited feature. Furthermore, unless otherwise specified, a component that "includes" or "has" an element or elements having a particular characteristic may additionally include other elements that do not possess that characteristic. As used herein, the phrase "at least one" should be interpreted as including the non-exclusive disjunction "or," i.e., A and / or B, etc., depending on the number of components.

[0012] In the drawings, like numerals indicate like or corresponding parts throughout the several views. Figure 1 shows a schematic of a processing system 10 for manufacturing a part 12. The processing system 10 can be used to improve the manufacturing process and for other benefits, some of which are described in more detail below.

[0013] The processing system 10 described herein can be used to manufacture parts 12 for a variety of applications, including, but not limited to, air vehicles such as aircraft, drones, payloads, space shuttles, and satellites; mobile platforms such as locomotives, high-speed trains, automobiles, off-road vehicles, surface vessels, trailers, and agricultural machinery; equipment, buildings, or other applications where the manufacturing processes described herein can be used on the parts 12.

[0014] Continuing to refer to FIG. 1, the part 12 may initially be a single workpiece 12 or multiple workpieces 12 in an assembled state or to be assembled, and the workpieces 12 may undergo one or more manufacturing processes to achieve a desired degree of completion of the part 12.

[0015] The part 12 may have any suitable configuration. Accordingly, the workpiece 12 may also have any suitable configuration. Typical, non-limiting examples of the part 12 include one or more panels, skins, frames, brackets, spars, chords, engine cowls, or other structural members or parts using the manufacturing processes described herein, and combinations thereof. As non-limiting examples of the part 12 for air vehicle applications, the part 12 may include one or more of a panel such as a wing, a fuselage, a skin such as a skin panel, a panel such as an inner panel or an outer panel, a frame, a bracket, a stringer, a bulkhead, a keel, a rib, a door, a fitting, etc., and combinations thereof.

[0016] The processing system 10 described herein is capable of performing many different manufacturing processes on a single workpiece 12, and even on multiple different workpieces 12. Thus, depending on the type of part 12, one or more manufacturing processes may be performed. Generally, the workpiece 12 has a work surface 14 on which various manufacturing processes may be performed to achieve a desired level of completion for the part 12. The manufacturing process may be any process suitable for the desired part 12, including, but not limited to, drilling, countersinking, cutting, assembling, fastening, welding, sealing, finishing, lubricating, measuring, probing, joining, splicing, and the like, and combinations thereof. Some example manufacturing processes are described below.

[0017] 1 , the processing system 10 further includes end effector tools 16A, 16B, and 16C capable of performing various manufacturing processes, as described in more detail below. A machine 18 may be used to control the end effector tools 16A, 16B, and 16C. Accordingly, the end effector tools 16A, 16B, and 16C may be coupled to the machine 18, such that the machine 18 may support the end effector tools 16A, 16B, and 16C. In this manner, the processing system 10 utilizes the machine 18 to automate the control of the end effector tools 16A, 16B, and 16C. The machine 18 may be configured to manipulate the end effector tools 16A, 16B, and 16C and / or move the end effector tools 16A, 16B, and 16C to desired positions.

[0018] Machine 18 may have any configuration suitable for controlling end effector tools 16A, 16B, 16C. By way of non-limiting example, machine 18 may include one or more of a robot, a robotic arm, a computer numerically controlled (CNC) machine, an automated machine, a factory machine, a crane, a manual lifting assembly, or other suitable machine 18 capable of controlling end effector tools 16A, 16B, 16C and / or moving end effector tools 16A, 16B, 16C to desired positions.

[0019] 1 , the end effector tools 16A, 16B, 16C may include a coupler 20 that forms an interface between the end effector tools 16A, 16B, 16C and a machine 18. The machine 18 includes corresponding features that are compatible with the coupler 20, thereby allowing the machine 18 to be attached to and detached from the end effector tools 16A, 16B, 16C via the coupler 20. Once the machine 18 is attached to the end effector tools 16A, 16B, 16C via the coupler 20, the machine 18 can move the end effector tools 16A, 16B, 16C to a desired position. The coupler 20 may have any suitable configuration, and non-limiting examples of the coupler 20 include one or more of quick-release mechanisms, eyelets, connectors, clips, fasteners, bolted connections, grab-and-go connections, magnets or magnetic connectors, vacuum connectors or vacuum pick-and-place connectors, etc.

[0020] As shown most clearly in FIGS. 1, 4, 6, and 10, each end effector tool 16A, 16B, 16C includes a fixture 22, and the coupler 20 can be mounted to the fixture 22. Generally, the fixture 22 supports multiple processing tools 24A, 24B, 24C, 24D. Thus, when the fixture 22 is mounted to a machine 18, multiple manufacturing processes (i.e., multiple of the same process or multiple different processes) can be performed on the single machine 18 because the fixture 22 is configured to support multiple processing tools 24A, 24B, 24C, 24D. The use of multiple processing tools 24A, 24B, 24C, 24D with a single end effector tool 16A, 16B, 16C can address the problem of low throughput or low work rate. Thus, using multiple processing tools 24A, 24B, 24C, and 24D with a single end effector tool 16A, 16B, and 16C can improve throughput and / or throughput, thereby improving production by the processing system 10. For example, using the processing system 10 described herein can reduce manufacturing process time and increase workpiece productivity. Furthermore, using multiple processing tools 24A, 24B, 24C, and 24D with a single end effector tool 16A, 16B, and 16C can reduce the amount of human interaction required for one or more manufacturing processes. Thus, the processing system 10 described herein can reduce costs and manufacturing complexity. Some example configurations of the processing tools 24A, 24B, 24C, and 24D are described below.

[0021] 1, 4, 6, and 10, the processing tools 24A, 24B, 24C, and 24D are positioned relative to one another in a suitable manner. The processing tools 24A, 24B, 24C, and 24D can be positioned depending on the desired location of the workpiece 12 to be processed. For example, the processing tools 24A, 24B, 24C, and 24D can be positioned in rows or columns relative to the fixture 22, or can be offset from one another.

[0022] 1, machine 18 holds end effector tools 16A, 16B, and 16C relative to workpiece 12. As shown, a portion of fixture 22 has a complimentary contour to work surface 14 of workpiece 12 and serves to position processing tools 24A, 24B, 24C, and 24D to a similar contour, thereby positioning all of processing tools 24A, 24B, 24C, and 24D at a fixed distance relative to work surface 14 of workpiece 12 prior to manipulating processing tools 24A, 24B, 24C, and 24D. Thus, for example, when processing tools 24A, 24B, 24C, and 24D are extended toward and perform operations on work surface 14, each processing tool 24A, 24B, 24C, and 24D can move the same distance toward work surface 14 because processing tools 24A, 24B, 24C, and 24D are positioned complementary to the contours of work surface 14. However, optionally, one or more of processing tools 24A, 24B, 24C, and 24D can move a greater or lesser distance relative to work surface 14 than the other processing tools 24A, 24B, 24C, and 24D.

[0023] Thus, for example, as best shown with reference to FIG. 1 , portions of the work surface 14 and the end effector tools 16A, 16B, 16C have congruent contours. Therefore, the work surface 14 assumes a first configuration, and operations can be performed on the work surface 14 to advance processing of the part 12. With reference to FIGS. 1 and 3 , the fixture 22 includes a fixture platform 26 having an exterior surface 28 that assumes a second configuration that is complementary to the first configuration of the work surface 14. The complementary features of the fixture platform 26 and the work surface 14 are the surfaces that face each other, as best shown in FIG. 1 . That is, as shown in FIG. 1 , when the end effector tools 16A, 16B, 16C are positioned adjacent to the workpiece 12, the work surface 14 of the workpiece 12 and the exterior surface 28 of the fixture platform 26 face each other, and these surfaces 14, 28 are generally complementary. It should be noted that the first configuration of the work surface 14 and the second configuration of the fixture platform 26 may be any suitable configuration, non-limiting examples of which include arcuate, flat, wavy, angled, tapered, etc.

[0024] In some configurations, the workpiece 12 is an aircraft panel, although the workpiece 12 can have other configurations, and the following description of a panel is exemplary. In some configurations, the panel is arcuate with a convex and / or concave orientation, and therefore, the first configuration of the work surface 14 is arcuate with a convex and / or concave orientation. Similarly, in some configurations, the second configuration of the exterior surface 28 of the fixture platform 26 is arcuate with an opposite convex and / or concave orientation to the work surface 14, such that the work surface 14 and the fixture platform 26 are complementary. Thus, depending on the orientation of the work surface 14, the fixture platform 26 is configured with an opposite orientation, such that the fixture platform 26 is generally complementary to the work surface 14. Thus, when workpiece 12 is oriented as shown in FIG. 1, work surface 14 is arcuate in a convex orientation and fixture platform 26 is complementary to work surface 14 in a concave orientation, such that fixture platform 26 is generally complementary to work surface 14.

[0025] As described above, the end effector tools 16A, 16B, 16C include processing tools 24A, 24B, 24C, 24D, which may have a variety of configurations depending on the desired process or processes to be performed on the workpiece 12. Each processing tool 24A, 24B, 24C, 24D may be configured to perform the same or different operations.

[0026] For example, end effector tools 16A, 16B, 16C further include a set of first processing tools 24A, 24B, 24C, 24D mounted in fixture 22 in a predetermined pattern. First processing tools 24A, 24B, 24C, 24D are configured to perform operations on work surface 14. Accordingly, first set of processing tools 24A, 24B, 24C, 24D are configured to perform the same operation. That is, first processing tools 24A, 24B, 24C, 24D are arranged throughout fixture 22 according to a template.

[0027] In some configurations, the end effector tools 16A, 16B, 16C further include a set of second processing tools 24A, 24B, 24C, 24D mounted in the fixture 22 in a predetermined pattern. The second processing tools 24A, 24B, 24C, 24D are configured to perform operations on the work surface 14. Accordingly, the second set of processing tools 24A, 24B, 24C, 24D are configured to perform the same operations. That is, the second processing tools 24A, 24B, 24C, 24D are arranged throughout the fixture 22 according to a template.

[0028] The predetermined pattern or template formed through the processing tools 24A, 24B, 24C, and 24D throughout the fixture 22 is designed to position the processing tools 24A, 24B, 24C, and 24D so that the processing system 10 can perform its operating cycles in precise locations consistent with the design of the workpiece 12.

[0029] In some configurations, each of the first processing tools 24A, 24B, 24C, 24D may be configured to perform one operation, and each of the second processing tools 24A, 24B, 24C, 24D may be configured to perform a different operation than the first processing tools 24A, 24B, 24C, 24D. That is, the first processing tools 24A, 24B, 24C, 24D may be configured to perform a first operation on the work surface 14, and the second processing tools 24A, 24B, 24C, 24D may be configured to perform a second operation on the work surface 14.

[0030] Optionally, the end effector tool 16C may incorporate a first set of processing tools 24A and a second set of processing tools 24B, as shown in FIG. 4. Thus, in some configurations, the second set of processing tools 24B may be mounted in the fixture 22 adjacent to the first set of processing tools 24A. However, the end effector tool 16C may incorporate more processing tools in addition to the first set of processing tools 24A and the second set of processing tools 24B. That is, the end effector tool 16C may incorporate any suitable number of sets of different processing tools 24A, 24B, 24C, and 24D.

[0031] Alternatively, in other configurations, different end effector tools 16A, 16B, 16C may be interchangeable in machine 18. That is, each end effector tool 16A, 16B, 16C may support a different type of processing tool 24A, 24B, 24C, 24D. That is, with reference to FIG. 6, a set of processing tools 24A, 24B, 24C, 24D are secured to fixture 22 of a single end effector tool 16A, 16B, 16C; in this example, processing tool 24A, 24B, 24C, 24D may be referred to as a first processing tool 24A. Referring now to FIG. 10, another set of processing tools 24A, 24B, 24C, 24D are secured to fixtures 22 of one end effector tool 16A, 16B, 16C, and in this example, processing tools 24A, 24B, 24C, 24D can be referred to as second processing tools 24B.

[0032] Thus, optionally, the end effector tools 16A, 16B, 16C may be further defined as a first end effector tool 16A having a first set of processing tools 24A (see FIG. 6), and the processing system 10 may further include a second end effector tool 16B having a set of second processing tools 24B (see FIG. 10). That is, the machine 18 may operate the first end effector tool 16A for a particular workpiece 12 or a particular process, and then the machine 18 may disconnect from the first end effector tool 16A and connect to the second end effector tool 16B, which operates on the particular workpiece 12 or for another process. The first end effector tool 16A and the second end effector tool 16B are interchangeable and may perform different operations on the work surface 14.

[0033] Depending on the configuration of the part 12, different parts 12 may require different end effector tools 16A, 16B, 16C. Thus, in other configurations, a first end effector tool 16A may have processing tools 24A, 24B, 24C, 24D mounted on the fixture platform 26 in a different pattern than the other first end effector tools 16A, thereby accommodating multiple different processing regions for various workpiece configurations. Similarly, a second end effector tool 16B may have processing tools 24A, 24B, 24C, 24D mounted on the fixture platform 26 in a different pattern than the other second end effector tools 16B, thereby accommodating multiple different processing regions for various workpiece configurations. Additionally, in other configurations, the fixture platform 26 of a first end effector tool 16A may have one configuration to accommodate one configuration of the work surface 14, and the fixture platform 26 of another first end effector tool 16A may have a different configuration to accommodate a different configuration of the work surface 14. Similarly, the fixture platform 26 of a second end effector tool 16B may have one configuration to accommodate one configuration of the work surface 14, and the fixture platform 26 of another second end effector tool 16B may have a different configuration to accommodate a different configuration of the work surface 14.

[0034] The first processing tools 24A, 24B, 24C, 24D and the second processing tools 24A, 24B, 24C, 24D may be any suitable tools mountable to the fixture platform 26, and non-limiting examples of the first processing tools 24A, 24B, 24C, 24D and the second processing tools 24A, 24B, 24C, 24D are described herein. Note that the processing tools 24A, 24B, 24C, 24D are referred to as the first processing tool 24A or the second processing tool 24B for convenience of description. Thus, the processing tools 24A, 24B, 24C, 24D in FIG. 6 could also be referred to as the second processing tool 24B, and the processing tools 24A, 24B, 24C, 24D in FIG. 10 could also be referred to as the first processing tool 24A, or vice versa.

[0035] The processing system 10 accurately positions the end effector tools 16A, 16B, and 16C relative to the workpiece 12, thereby enabling consistent manufacturing repeatability. As described above, the machine 18 moves the end effector tools 16A, 16B, and 16C to desired positions relative to the work surface 14. Referring to FIGS. 1 and 2, the end effector tools 16A, 16B, and 16C may include multiple position sensors 30 connected to the fixture 22. Generally, the position sensors 30 are configured to position the end effector tools 16A, 16B, and 16C relative to the workpiece 12. More specifically, the position sensors 30 are configured to align the end effector tools 16A, 16B, and 16C relative to the workpiece 12, thereby aligning the processing tools 24A, 24B, 24C, and 24D, i.e., first processing tool 24A, second processing tool 24B, etc., in a predetermined position. That is, various positioning elements may be implemented to properly position the processing tools 24A, 24B, 24C, 24D relative to the work surface 14. The positioning of the end effector tools 16A, 16B, 16C may be recorded and analyzed utilizing the position sensors 30. That is, feedback may be obtained via the position sensors 30 and used to position the processing tools 24A, 24B, 24C, 24D in desired positions relative to the work surface 14. For example, in some configurations, one of the position sensors 30 sets the x, y, and z offsets, while other position sensors 30 set the i, j, and k offsets.

[0036] In some configurations, the position sensor 30 may include a camera assembly, a vision assembly, a laser assembly, a light assembly, a measurement assembly, etc. Thus, the position sensor 30 may include features for vision, infrared, thermo-heat signature, etc., to accurately position / locate the processing tools 24A, 24B, 24C, 24D relative to the work surface 14.

[0037] Depending on the type of position sensor 30 implemented, the workpiece 12 may optionally include at least one reference guide 32 (see FIG. 1 ). The reference guide 32 may be implemented in combination with the position sensor 30 to aid in positioning the end effector tools 16A, 16B, 16C relative to the workpiece 12. The position sensor 30 is configured to identify the reference guide 32 to position the end effector tools 16A, 16B, 16C relative to the work surface 14, thereby aligning the processing tools 24A, 24B, 24C, 24D, i.e., first processing tool 24A, second processing tool 24B, etc., in a predetermined position.

[0038] The reference guides 32 may have any suitable configuration or function, and non-limiting examples of the reference guides 32 may include lines, marks, etchings, stickers, projected patterns, optical reference points such as external optical reference points, magnetic reference targets, etc. An example of an external optical reference point is activating one or more lasers to indicate a location to which the machine 18 should move relative to the workpiece 12, and the position sensors 30 of the end effector tools 16A, 16B, 16C identify the location of the laser points to align the processing tools 24A, 24B, 24C, 24D relative to the work surface 14. An example of a magnetic reference target is placing one or more magnets within or on the backside of the workpiece 12, and the position sensors 30 of the end effector tools 16A, 16B, 16C identify the location of the magnets to align the processing tools 24A, 24B, 24C, 24D relative to the work surface 14. It should be noted that any suitable number of reference guides 32 may be implemented. Position sensor 30 and reference guide 32 may optionally be implemented in place of tooling holes and corresponding tooling rods, although tooling holes and corresponding tooling rods may be implemented to position end effector tools 16A, 16B, 16C relative to workpiece 12, if desired.

[0039] Generally, the position sensors 30 are mounted to the fixture 22. In some configurations, the position sensors 30 are mounted to the fixture platform 26. The position sensors 30 are spaced apart from one another around the periphery of the fixture 22, and more specifically, relative to the fixture platform 26. Figures 1, 3-6, and 10 show non-limiting examples of where the position sensors 30 may be mounted on the fixture 22 or fixture platform 26. More or fewer position sensors 30 may be implemented than shown.

[0040] In some configurations, the fixture platform 26 may include a perimeter 34 that surrounds the processing tools 24A, 24B, 24C, and 24D. Optionally, the position sensor 30 may be located proximate the perimeter 34, and in some configurations, the position sensor 30 may be attached to the perimeter 34. By locating the position sensor 30 on the perimeter 34, the position sensor 30 may be able to position the end effector tools 16A, 16B, and 16C relative to the workpiece 12 over a wider range than if the position sensor 30 were located elsewhere. Optionally, the position sensor 30 may be movable relative to the fixture 22, and more specifically, the position sensor may be movable relative to the fixture platform 26, thereby adjusting the range over which the end effector tools 16A, 16B, and 16C are positioned relative to the workpiece 12. Having a movable position sensor 30 may provide a wider positioning range (e.g., a wider field of view) than would be possible with a fixed position sensor.

[0041] In some configurations, the position sensor 30 may be configured to perform quality control of the workpiece 12. That is, the position sensor 30 may acquire data about the workpiece 12 using, for example, visual or infrared light, and the collected data may be used by another system to analyze the data and make a determination about the workpiece 12, such as a determination about the quality of the workpiece 12.

[0042] A controller 36 is implemented to control various functions of the processing system 10. Thus, with reference to Figures 1 and 2, the processing system 10 may further include a controller 36 in communication with the end effector tools 16A, 16B, and 16C. The controller 36 controls the operation of the machine 18, the processing tools 24A, 24B, 24C, and 24D, and other functions, some of which are described in more detail below. Additionally, the controller 36 may collect data, analyze the data, and / or make decisions based on various data. For example, the controller 36 may be programmed to collect data regarding the workpiece 12 and / or the part 12 during any part of the manufacturing process and make various decisions regarding quality control of the workpiece 12 or part 12. Further control functions of the controller 36 are described in more detail below.

[0043] The controller 36 can communicate with the various functional units of the end effector tools 16A, 16B, 16C via an electrical interface or module 37 (see FIG. 2 ). The controller 36 includes a processor P configured to execute instructions from a memory M. The processing circuitry can include one or more processors P alone or in combination with one or more memories. The processing circuitry is generally any computer hardware configured to process information, such as data, computer programs, and / or other suitable electronic information. The processing circuitry is comprised of a collection of electronic circuits, some of which are packaged as an integrated circuit or as multiple interconnected integrated circuits (integrated circuits are sometimes commonly referred to as a “chip”). The processing circuitry can be configured to execute computer programs, for example, stored within the processing circuitry or stored in memory M of the same controller 36 or a different controller 36.

[0044] The processing circuitry may include multiple processors P, multi-core processors, or other types of processors, depending on the particular implementation. Furthermore, the processing circuitry may be implemented using heterogeneous processor systems, in which a primary processor is provided on a single chip along with secondary processors. As another example, the processing circuitry may be a symmetric multiprocessor system including multiple processors of the same type. Thus, while the processing circuitry may be configured to execute a computer program to perform one or more functions, the processing circuitry in various embodiments may also be configured to perform one or more functions without the aid of a computer program. In either case, the processing circuitry may be appropriately programmed to perform functions and operations in accordance with exemplary embodiments of the present disclosure.

[0045] The memory M is generally any computer hardware configured to temporarily and / or permanently store information such as data, computer programs (e.g., computer-readable program code), and / or other suitable information. The memory M may include, for example, volatile and / or non-volatile memory and may be fixed or removable. Non-limiting examples of suitable memory M may include random access memory (RAM), read-only memory (ROM), hard drives, flash memory, thumb drives, removable computer diskettes, optical disks, magnetic tapes, or combinations thereof. Optical disks may include compact disk read-only memory (CD-ROM), read / write compact disks (CD-R / W), DVDs, etc. In various examples, the memory M may be referred to as a computer-readable storage medium. A computer-readable storage medium may also be a non-transitory device configured to store information. The computer-readable medium described herein may generally refer to a computer-readable storage medium or a computer-readable transmission medium.

[0046] In addition to the memory M, the processing circuitry may be connected to one or more interfaces for displaying, transmitting, and / or receiving information. The interfaces may include a communication interface (e.g., a communication unit) and / or one or more user interfaces. The communication interface may be configured to transmit and receive information to, for example, other device(s), network(s), etc. The communication interface may be configured to transmit and receive information via physical (wired) and / or wireless communication links. Examples of suitable communication interfaces include a network interface controller (NIC), a wireless NIC (WNIC), etc.

[0047] Returning to the end effector tools 16A, 16B, and 16C, the controller 36 can control not only a single machine 18 but also multiple processing tools 24A, 24B, 24C, and 24D mounted to the fixture 22 of the machine 18. In this manner, multiple processing tools 24A, 24B, 24C, and 24D mounted to the fixture 22 of a single end effector tool 16A, 16B, and 16C can perform high-speed and / or high-volume manufacturing processes on a single machine 18, compared to machines with a single processing tool, as described in the Background section above. The compactness of the end effector tools 16A, 16B, and 16C allows for a reduced capacity and cost for the machine 18. Furthermore, the machine 18 allows for the use of cooperating machines 18 with lower payload capacities, thereby improving manufacturing efficiency at a facility.

[0048] The controller 36 is configured to control the movement of the end effector tools 16A, 16B, 16C to position the processing tools 24A, 24B, 24C, 24D, i.e., first processing tool 24A, second processing tool 24B, etc., relative to the work surface 14 such that a predetermined pattern is aligned at a predetermined position relative to the work surface 14. The controller 36 is further configured to control the operation of the first processing tool 24A, such that the first processing tool 24A performs an operation on the work surface 14 to form a first processing region 38 at a predetermined location on the work surface 14. Similarly, the controller 36 is further configured to control the operation of the second processing tool 24B, such that the second processing tool 24B performs an operation on the work surface 14 to form a second processing region 38 at a predetermined location on the work surface 14. Thus, the controller 36 is configured to control the operation of any number of processing tools 24A, 24B, 24C, 24D to form their respective processing regions 38.

[0049] For ease of explanation, one processing region 38 is shown in Figure 1 and is identified as a first processing region 38. The machine 18 positions the end effector tools 16A, 16B, 16C at other predetermined locations to form other processing regions 38, such as a second processing region 38, depending on the number of processing regions desired.

[0050] The controller 36 can activate the processing tools 24A, 24B, 24C, and 24D in any order. For example, the processing tools 24A, 24B, 24C, and 24D can be activated individually, one at a time, in a pattern, simultaneously, or in any combination or group.

[0051] Referring now to the position sensor 30, the controller 36 can communicate with the position sensor 30 to position the end effector tools 16A, 16B, 16C relative to the workpiece 12. For example, the controller 36 can use data from the position sensor 30 and / or the reference guide 32 to properly align the processing tools 24A, 24B, 24C, 24D relative to the work surface 14. Additionally, the controller 36 can use data from the position sensor 30 to determine whether the workpiece 12 is within a desired quality control range.

[0052] Features can be implemented to secure and / or stabilize the fixture 22 relative to the workpiece 12 after the processing tools 24A, 24B, 24C, 24D are aligned in place. Thus, for example, the end effector tools 16A, 16B, 16C can further include an end effector mount assembly 40 (see FIGS. 3, 5, 6, and 10), which is configured to engage the workpiece 12 to secure the end effector tools 16A, 16B, 16C in place. A controller 36 can be in communication with the end effector mount assembly 40, such that the controller 36 can be used to selectively activate and deactivate the end effector mount assembly 40, as described in more detail below.

[0053] 3, 5, 6, and 10, the end effector mounting assembly 40 may include a plurality of holders 42 mounted to the fixture 22. The holders 42 are configured to engage the workpiece 12 to mount the end effector tools 16A, 16B, 16C to the workpiece 12, thereby enabling one or more manufacturing processes to be performed on the workpiece 12 while the end effector tools 16A, 16B, 16C are held in place relative to the workpiece 12. Additionally, the holders 42 may be configured to absorb energy, dampen vibrations, and / or provide compliance during operation of the processing tools 24A, 24B, 24C, 24D, thereby maintaining the fixture 22, and thus the processing tools 24A, 24B, 24C, 24D, in a desired position, thereby reducing or avoiding distortion of the workpiece 12 during manufacturing.

[0054] Generally, the holders 42 are spaced apart from one another around the periphery of the fixture 22, and more specifically, around the periphery of the fixture platform 26. The holders 42 may be positioned in a gap 44 (see FIGS. 8A-8D ) between the fixture platform 26 and the workpiece 12. That is, the fixture 22 and the fixture platform 26 maintain a spaced-apart relationship from the workpiece 12 via the holders 42 during the manufacturing process. Any suitable number of holders 42 may be implemented. In some configurations, the holders 42 are further defined as suction cups. Note that the holders 42 may have any suitable configuration, with suction cups being merely one example. Other non-limiting examples include magnets, fasteners that pass through existing holes, expanding mandrels that pass through existing holes, mechanisms that apply pressure to the backside of the workpiece 12, etc.

[0055] 2, the end effector mounting assembly 40 may include a vacuum assembly 46 in fluid communication with the holders 42. More specifically, the vacuum assembly 46 may include a pump 48A and a plurality of conduits 50 connected to the pumps 48A. The conduits 50 are also connected to each of the holders 42, thereby placing the pumps 48A in fluid communication with the holders 42.

[0056] The vacuum assembly 46 is activated or deactivated by the controller 36, which correspondingly controls whether the holder 42 secures the end effector tools 16A, 16B, 16C to the workpiece 12. Thus, the controller 36 is configured to activate the vacuum assembly 46 when the holder 42 is engaged with the workpiece 12, thereby creating a suction force between the holder 42 and the workpiece 12 to vacuum-attach the end effector tools 16A, 16B, 16C in place relative to the workpiece 12. That is, when it is desired to attach the end effector tools 16A, 16B, 16C to the workpiece 12, the pump 48A of the vacuum assembly 46 is activated to remove fluid from the space between the holder 42 and the workpiece 12 and create a low pressure between the holder 42 and the workpiece 12 (compared to the outside of the holder 42, which is at atmospheric pressure), thereby attracting the holder 42 to the workpiece 12 and attaching the end effector tools 16A, 16B, 16C to the workpiece 12. To remove the end effector tools 16A, 16B, 16C from the workpiece 12, the pump 48A is stopped and the space between the holder 42 and the workpiece 12 is filled with fluid, or the pump 48A is started and fluid is supplied to the space between the holder 42 and the workpiece 12, thereby increasing the pressure between the holder 42 and the workpiece 12 and releasing the suction, thereby allowing the holder 42 to be removed from the workpiece 12.

[0057] The controller 36 can be configured to activate, deactivate, and / or adjust the vacuum assemblies 46 of any of the multiple holders 42 as needed. Additionally, the controller 36 can be configured to increase or decrease the vacuum pressure to adjust or change the holding force between each holder 42 and the workpiece 12. The controller 36 can control the vacuum assemblies 46 to activate each holder 42 in any suitable arrangement. For example, the holders 42 can be activated individually, in a pattern, simultaneously, or in any combination or group. The controller 36 can be programmed to control the engagement of the holders 42 with the workpiece 12. In this manner, the controller 36 can optimize the activation strategy to manage air consumption, control energy absorption, and / or control vibration damping.

[0058] Directional flow control valves and pressure regulators may be implemented to control the holders 42 and / or the sequence in which the holders 42 engage the workpieces 12. Thus, the controller 36 may be in communication with the control valves and pressure regulators.

[0059] As described above, the controller 36 can control the processing tools 24A, 24B, 24C, and 24D, i.e., the first processing tool 24A, the second processing tool 24B, etc., as needed. For example, one or more of the processing tools 24A, 24B, 24C, and 24D can be operated sequentially, in a pattern, in a particular order, simultaneously, or randomly. Generally, a portion of each first processing tool 24A can be moved relative to the fixture 22 and through the fixture platform 26 as operations are performed on the work surface 14. That is, the controller 36 can activate each processing tool 24A, 24B, 24C, and 24D and move a portion of each processing tool 24A, 24B, 24C, and 24D toward or away from the work surface 14. The movement and operation of the processing tools 24A, 24B, 24C, 24D and their corresponding functions may be controlled by mechanical, pneumatic, hydraulic, electrical, or other suitable mechanisms, or by any combination thereof.

[0060] In some configurations, the controller 36 is configured to simultaneously control the operation of each of the processing tools 24A, 24B, 24C, and 24D, such as the first processing tool 24A and the second processing tool 24B. Thus, for example, once the fixture 22 is positioned relative to the workpiece 12, the controller 36 can simultaneously activate each of the processing tools 24A, 24B, 24C, and 24D. Thus, for example, if each of the processing tools 24A is configured to drill holes 52, the controller 36 can activate these processing tools 24A to simultaneously drill holes in predetermined locations in the workpiece 12 in a predetermined pattern. As another example, continuing with the drilling example above, the processing tools 24A can be activated one at a time or in a predetermined pattern, such as in groups.

[0061] As described above, various processing tools 24A, 24B, 24C, and 24D may be mounted to fixture 22, and more particularly fixture platform 26. Furthermore, processing tools 24A, 24B, 24C, and 24D may perform various manufacturing processes. By way of non-limiting example, processing tools 24A, 24B, 24C, and 24D may form holes 52 and / or countersinks 54, perform measurements, apply sealants, coatings, and the like, and insert fasteners into workpiece 12, some of which operations are described below. Details of non-limiting examples of these processing tools 24A, 24B, 24C, and 24D are now described.

[0062] 7, 8A-8D, 9A, and 9B, the processing tool 24A can be configured to drill a hole 52, which may include a countersink 54, a spot face, a spot face, etc., in the workpiece 12, as desired. Thus, in some configurations of the processing tools 24A, 24B, 24C, 24D, the processing tool 24A may be a drill assembly 56.

[0063] In some configurations, the end effector tool 16A may include only the drill assembly 56 attached to the fixture 22, as shown in Figure 6. In other configurations, the end effector tool 16C may include one or more other processing tools 24B, 24C, 24D in addition to the drill assembly 56, as shown in Figure 4.

[0064] During the drilling process / operation, the end effector tools 16A, 16C may generate forces such as reaction forces, vibrations, and torques, which may be transmitted to the workpiece 12. To reduce or avoid the transmission of these forces, vibrations, torques, and the like to the workpiece 12 during processing, the holder 42, which interfaces between the fixture 22 and the workpiece 12, is configured to absorb energy, dampen vibrations, and / or provide flexibility during operation of the processing tools 24A, 24B, 24C, and 24D, thereby maintaining the fixture 22 and, therefore, the processing tools 24A, 24B, 24C, and 24D in a desired position, thereby reducing or avoiding distortion of the workpiece 12 during manufacturing. The holder 42 thus helps absorb reaction forces and / or vibrations, reducing or avoiding distortion of the workpiece 12 due to drilling and minimizing adverse effects during the drilling process / operation. The holder 42 may be positioned at an appropriate location around one or more of the drill assemblies 56.

[0065] When one type of processing tool 24A, 24B, 24C, 24D is attached to the end effector tools 16A, 16B, in some configurations, each of the first processing tools 24A may be a drill assembly 56. When two or more types of processing tools 24A, 24B, 24C, 24D are attached to the end effector tool 16C, the first processing tool 24A or the second processing tool 24B, etc. may be a drill assembly 56. That is, when the first processing tool 24A is a drill assembly 56, the second processing tools 24B, 24C, 24D are different types of processing tools 24B, 24C, 24D other than the drill assembly 56. Alternatively, when the first processing tools 24B, 24C, 24D are not drill assemblies 56, the second processing tool 24A may be a drill assembly 56.

[0066] 6 and 7, each of the processing tools 24A, 24B, 24C, 24D (hereinafter referred to as the first processing tool 24A for convenience of explanation) can include a drill assembly 56 configured to form holes 52 (see FIG. 1) in the work surface 14. The drill assembly 56 of each of the first processing tools 24A is configured to form holes 52 in the work surface 14, thereby forming the first processing region 38 in a predetermined location, forming a pattern of holes 52. Referring to FIG. 1, one non-limiting example of a pattern of holes 52 is shown, which is also a non-limiting example of the first processing region 38 with one arrangement of one end effector tool 16A, 16B, 16C.

[0067] Optionally, each drill assembly 56 of the first processing tool 24A is further configured to form a countersink 54 (see FIGS. 12A and 12B) aligned with the hole 52 in the work surface 14. That is, each drill assembly 56 can form the hole 52 and / or the countersink 54, and the hole 52 and the countersink 54 can be formed simultaneously or the hole 52 and the countersink 54 can be formed in separate steps.

[0068] Regardless of the configuration of the hole 52 being formed, the following description of the features of the drill assembly 56 applies to the present disclosure unless otherwise stated. The features of the drill assembly 56 will be described with reference to Figures 7 and 8A-8D.

[0069] The drill assembly 56 of each first processing tool 24A may include a drill 58 having a machine bit 60. The drill 58 of each processing tool 24A is configured to manipulate the machine bit 60 to form a hole 52 in the work surface 14. Accordingly, the machine bit 60 may be a cutter, punch, or other suitable machine bit 60 for forming a hole 52, a countersink 54, a spot face, a spot face, or the like. Optionally, the machine bits 60 of each processing tool 24A may be the same in a single end effector tool 16A, 16C to form the same hole 52. Optionally, one or more of the machine bits 60 of a processing tool 24A may be different from one another in a single end effector tool 16A, 16C to form different types of holes 52. Optionally, one or more machine bits 60 of a processing tool 24A may form one or more holes 52 of different sizes in a single end effector tool 16A, 16C.

[0070] Vibrations may occur during operation of the drill 58 of each processing tool 24A. Accordingly, the drill assembly 56 may include one or more sensors 62 for detecting data about vibrations during drilling operations. The sensors 62 may be any suitable sensors, and non-limiting examples of the sensors 62 include one or more of a vibration sensor, a distance sensor, and / or a flow sensor. The sensors 62 may be in communication with the controller 36, which may collect and analyze the data and / or determine whether to adjust or stop each drill 58. In some configurations, the controller 36 may compare actual vibration data obtained from the operation of each drill 58 with a reference vibration profile. The drill 58 of each processing tool 24A may be individually adjustable via the controller 36, and this adjustment may be the position of the drill 58 and / or the speed of the positive feed drill 58 for drilling a hole in the workpiece 12. Alternatively, one or more of the drills 58 may be adjusted via the controller 36 by stopping the desired drill 58. The reference vibration may be a predetermined threshold value of a vibration level, which may be set as appropriate based on engineering requirements, government requirements, etc. When a threshold value is referred to in this specification, this threshold value may be set as appropriate based on engineering requirements, government requirements, etc.

[0071] To operate the machine bits 60, the drill assembly 56 of each first processing tool 24A may include a drill actuator 64 connected to the machine bits 60, the drill actuator 64 configured to selectively operate the machine bits 60. The controller 36 is configured to control the operation of the drills 58 of each first processing tool 24A such that the machine bits 60 of each drill 58 form respective holes 52 in the work surface 14, forming a pattern of holes 52 at predetermined locations. Thus, for example, the controller 36 may control the operation of the drill actuators 64 of each processing tool 24A such that the rotation of the machine bits 60 is selectively started or stopped to cut the work surface 14. The drill actuators 64 may take any suitable configuration, non-limiting examples of which may include a motor, such as an electric motor, a hydraulic motor, a pneumatic motor, or the like.

[0072] The drill assembly 56 of each processing tool 24A may be a positive feed drill assembly (see FIGS. 8A-8D) capable of applying a drilling thrust. Accordingly, the drill assembly 56 of each first processing tool 24A may include a drill feed actuator 66 connected to the drill 58, the drill feed actuator 66 configured to control movement of the drill 58 relative to the workpiece 12. Accordingly, the drill assembly 56 of each first processing tool 24A may be configured to move the machining bit 60 along a longitudinal axis 68 between a retracted position (see FIGS. 8A and 8D) and an extended position (see FIG. 8C). That is, the drill 58 and its corresponding machining bit 60 may be moved toward or away from the workpiece 12 via the drill feed actuator 66 depending on the stage of formation of the hole 52. As shown in FIG. 8C, activation of the drill feed actuator 66 moves the drill 58 in the direction of arrow H to perform an operation on the workpiece 12. After the drilling operation is completed, activation of the drill feed actuator 66 moves the drill 58 in the direction of arrow I to return the drill to the retracted position. The controller 36 is in communication with a drill feed actuator 66 of each processing tool 24 A to control the movement of the respective drill 58 along a longitudinal axis 68 .

[0073] The drill feed actuator 66 of the processing tool 24A may have any suitable configuration, and non-limiting examples of the drill feed actuator 66 may include a mechanical actuator, a pneumatic actuator, a hydraulic actuator, an electric actuator, a motor, or other suitable mechanism.

[0074] 8A-8D, the drill assembly 56 of each first processing tool 24A may include a drill 58 and a drill feed bracket 70 attached to a drill feed actuator 66, such that the drill feed bracket 70 and the drill 58 can move simultaneously with respect to one another via the drill feed actuator 66. Thus, the drill feed bracket 70 of the processing tool 24A supports the drill 58.

[0075] Additionally, features may be implemented to assist in stabilizing the drill assembly 56 of each processing tool 24A during a drilling operation. Accordingly, with reference to FIGS. 7 and 8A-8D, the drill assembly 56 of each first processing tool 24A may include a clamp 72 connected to the drill 58 and a clamp actuator 74 attached to the clamp 72. The clamp actuator 74 of the drill assembly 56 of each first processing tool 24A is configured to move the clamp 72 in the direction of arrow G to a locked position (see FIGS. 8B and 8C). In the locked position, the clamp 72 engages the workpiece 12 to stabilize the drill 58 relative to the work surface 14 during a drilling operation. The clamp actuator 74 is also configured to move the clamp 72 in the direction of arrow J to an unlocked position (see FIGS. 8A and 8D). In the unlocked position, the clamp 72 is spaced from the workpiece 12. That is, a face 75 of the clamp 72 abuts the workpiece 12 in the locked position. During a drilling operation, the clamps 72 of the processing tool 24A apply pressure against the work surface 14 via operation of the clamp actuators 74 to stabilize the drill 58 against the work surface 14. This can reduce or prevent deformation of the hole 52 and reduce or prevent chatter of the work surface 14 during the drilling operation. The controller 36 is in communication with the clamp actuators 74 of each processing tool 24A and can control operation of the respective clamp actuators 74, which in turn can control operation of the respective clamps 72.

[0076] The clamp actuator 74 of the processing tool 24A may have any suitable configuration, and non-limiting examples of the clamp actuator 74 may include a mechanical actuator, a pneumatic actuator, a hydraulic actuator, an electric actuator, a motor, or other suitable mechanism.

[0077] The drill assembly 56 of each first processing tool 24A may include a feed stop 76 that limits movement of the drill 58 toward the workpiece 12 when the drill feed bracket 70 contacts the feed stop 76. Generally, the feed stop 76 of the processing tool 24A is disposed between the drill feed bracket 70 and the workpiece 12. In some configurations, each feed stop 76 is secured to a clamp 72, such that a portion of the drill feed bracket 70 contacts the feed stop 76 when the maximum feed distance is reached. However, the feed stop 76 of the processing tool 24A may be secured to any suitable structure to limit movement of the drill 58 toward the workpiece 12.

[0078] Optionally, the feed stop 76 of each processing tool 24A may be adjustable to accommodate different maximum feed distances of the drill 58. Adjusting the feed stop 76 of the processing tool 24A may accommodate countersinks 54 of different depths and may also accommodate adjustments to the countersink 54. That is, the height of the feed stop 76 of each processing tool 24A is adjustable along the longitudinal axis 68, thereby changing the maximum feed distance of each respective drill 58.

[0079] In this configuration, one or more feed stops 76 of the processing tool 24A can be adjusted manually or automatically by one or more actuators. If one or more feed stops 76 of the processing tool 24A are adjustable by respective actuators, the controller 36 can communicate with these actuators to control the operation of the feed stops 76.

[0080] 6, the drill assembly 56 of each first processing tool 24A can include a platform 78 that is attached to the fixture 22 of the end effector tools 16A, 16C. The platform 78 secures the processing tools 24A, 24B, 24C, 24D relative to the end effector tools 16A, 16B, 16C, such that movement of the end effector tools 16A, 16B, 16C allows the entire set of processing tools 24A, 24B, 24C, 24D to be moved to a desired position. In some configurations, the platform 78 of each processing tool 24A, 24B, 24C, 24D is attached to the fixture platform 26.

[0081] 7, the platform 78 of the processing tool 24A defines an opening 80 through which the clamp 72 is movable between locked and unlocked positions and through which the drill 58 is movable between retracted and extended positions. That is, the opening 80 in the platform 78 of the processing tool 24A provides access to the work surface 14.

[0082] 7, the drill assembly 56 of each first processing tool 24A may include a support bracket 82A attached to its respective platform 78. The support bracket 82A of each processing tool 24A extends outwardly away from the platform 78 and away from the workpiece 12. The support bracket 82A of each processing tool 24A generally supports the drill assembly 56 relative to the fixture 22. The support bracket 82A of the processing tool 24A may be fixed relative to the platform 78 or may be coupled to the platform 78 for flexibility, as described in more detail below.

[0083] 7, the clamp actuator 74 and drill feed actuator 66 of each processing tool 24A are secured to a respective support bracket 82A. Thus, when each clamp actuator 74 is actuated, the clamp 72 can move relative to the support bracket 82A and platform 78. Furthermore, when each drill feed actuator 66 is actuated, the drill feed bracket 70 and corresponding drill 58 can move relative to the support bracket 82A and platform 78.

[0084] Additionally, optionally, the drill assemblies 56 of each processing tool 24A may include functionality to enable adaptive drilling, which allows the controller 36 to collect and analyze data to determine whether one or more of the drill assemblies 56 should deviate from normal operating procedures. For example, if there is insufficient power or air supplied to each drill assembly 56, operation of one or more of the drill assemblies 56 may be slowed or stopped. As another example, operation of one or more of the drill assemblies 56 may be slowed or stopped if excessive vibration occurs during operation.

[0085] Optionally, and referring to FIGS. 9A and 9B , the drill assembly 56 of each processing tool 24A may include a compliance assembly 84 configured to provide compliance to the drill 58 relative to the workpiece 12. That is, if the work surface 14 is not perpendicular to the drill 58 prior to a drilling operation, the compliance assembly 84 allows the drill 58 to self-align with the work surface 14. That is, the compliance assembly 84 allows the drill 58 to passively align the machine bit 60 with the work surface 14. To that end, the compliance assembly 84 of each processing tool 24A may include a plurality of biasers 86, such as biasing members, that enable relative movement between the platform 78 and the support bracket 82A. The biasers 86 may have any suitable configuration, non-limiting examples of which include active compliance mechanisms, such as coil springs, leaf springs, rubber contacts, air cushions, expandable bladders, compliance mechanisms actuated by one or more actuators, other passive compliance mechanisms, or the like, or combinations thereof.

[0086] The compliance assembly 84 of each processing tool 24A also includes a plurality of connectors 88 fixed to the platform 78 and coupled to the support bracket 82A, thereby allowing the support bracket 82A to move relative to the platform 78. One or more biasers 86 are attached to the connectors 88 and are spring-loaded to continuously apply a biasing force against the corresponding support bracket 82A. Thus, the biasers 86 of each processing tool 24A are spring-loaded on the connectors 88 to maintain the drill 58 perpendicular to the platform 78, as shown in FIG. 9A . However, as shown in FIG. 9B , when the drill assembly 56 approaches the work surface 14, the work surface 14 is not perpendicular to the platform 78 or perpendicular to the drill 58. Thus, when the clamps 72 apply pressure against the workpiece 12, the biasers 86 of the processing tools 24A cause the support brackets 82A to move (e.g., tilt or lift) relative to the platform 78, which in turn moves the drills 58 relative to the platform 78 and aligns the machined bits 60 with the work surface 14. Thus, the compliance assembly 84 of each processing tool 24A passively aligns the machined bits 60 with the work surface 14 when the clamps 72 are in the locked position, thereby self-aligning the holes 52, countersinks 54, etc. with the work surface 14.

[0087] 11, 12A, 12B, 13, 14A, 14B, 15A-15B, and 16, processing tools 24A, 24B, 24C, and 24D may be configured to measure properties of workpiece 12. Accordingly, in some configurations of processing tools 24A, 24B, 24C, and 24D, processing tool 24B may be a measurement device 90.

[0088] 4, the end effector tool 16C can include one or more other processing tools 24A, 24C, 24D, such as a drill assembly 56, in addition to a measurement device 90. When more than one type of processing tool 24A, 24B, 24C, 24D is attached to the end effector tool 16C, depending on the number of processing tools 24A, 24B, 24C, 24D installed, the first processing tool 24A can be the measurement device 90 and the second processing tool 24B can be the other type of processing tool 24A, 24C, 24D, or alternatively, the second processing tool 24B can be the measurement device 90 and the first processing tool 24A can be the other type of processing tool 24A, 24C, 24D.

[0089] In other configurations, the end effector tool 16B may only have the measurement device 90 attached to the fixture 22, as shown in FIG. 10 . If the end effector tool 16B has only one type of processing tools 24A, 24B, 24C, and 24D attached to it, each of the first processing tools 24A may be a measurement device 90. Thus, for example, the measurement device 90 may be referred to as the first processing tool 24A or the second processing tool 24B, depending on the processing tools 24A, 24B, 24C, and 24D attached to the end effector tools 16B and 16C. For ease of explanation, the first processing tool 24A is shown as the drill assembly 56 and the second processing tool 24B is shown as the measurement device 90 in the figures. However, as discussed herein, these processing tools 24A and 24B may be reversed. In the following description, the measurement device 90 will be referred to as the second processing tool 24B, although in some circumstances the measurement device 90 may be referred to as the first processing tool 24A.

[0090] 11 , each second processing tool 24B may include a measuring device 90 configured to measure characteristics of the workpiece 12. The measuring device 90 may take on a variety of configurations, non-limiting examples of which may include one or more of a camera assembly, a vision assembly, a distance sensor, a probe assembly 92, a linear scale, an optical distance sensor, an ultrasonic distance sensor, a magnetic strip, or the like, and combinations thereof, for measuring various characteristics of the workpiece 12. For ease of explanation, a probe assembly 92 is described below, but other configurations of the measuring device 90 may be attached to the fixture 22 to measure desired characteristics of the workpiece 12. For example, the measuring device 90 of the processing tool 24B may be configured to measure the dimensions of each hole 52, the depth of each hole 52, the surface quality of each hole 52, the surface quality of the work surface 14 and / or workpiece 12, the material quality of the workpiece 12, etc.

[0091] 11 , in some configurations, the measurement device 90 of each second processing tool 24B can include a probe assembly 92 configured to measure a characteristic of the workpiece 12. That is, the probe assembly 92 can be configured to measure a characteristic of the holes 52 in the workpiece 12. Thus, in order to operate the probe assembly 92, the holes 52 in the workpiece 12 are first formed. Thus, the work surface 14 of the workpiece 12 defines a plurality of holes 52 prior to operating the measurement device 90.

[0092] 11 , the probe assembly 92 of each second processing tool 24B may include a support bracket 82B attached to the fixture 22, and more specifically, to the fixture platform 26. The support bracket 82B of each processing tool 24B extends outward, away from the workpiece 12. The support bracket 82B of each processing tool 24B generally supports the probe assembly 92 relative to the fixture 22. The holder 42 is an interface between the fixture 22 and the workpiece 12, and is disposed in a gap 44 (see FIGS. 15A-15B ) between the fixture platform 26 (and / or support bracket 82B) and the workpiece 12.

[0093] The probe assembly 92 of each processing tool 24B may include a probe 94 configured to measure a property of the workpiece 12. More specifically, the probe assembly 92 of each second processing tool 24B may include a probe 94 insertable into a hole 52 in the work surface 14 to measure a property of the hole 52 (see FIGS. 12A and 12B). In some configurations, each second processing tool 24B may have a probe assembly 92 and associated functionalities. In other configurations, each second processing tool 24B may include a probe assembly 92.

[0094] As mentioned above, in some configurations, the probe assembly 92 is movable relative to the fixture 22 so that it can be moved toward or away from the workpiece 12. Accordingly, the probe assembly 92 of each processing tool 24B may be configured to move the probe 94 along the longitudinal axis 68 between a retracted position (see FIG. 13) and an extended position (see FIG. 12A). The extended position of the probe 94 may be such that the probe 94 is fully seated within the bore 52 or fully seated within the countersink 54 of the bore 52. Alternatively, the extended position of the probe 94 may be such that the probe 94 is inserted a desired distance into the bore 52.

[0095] Additionally, the probe assembly 92 of each second processing tool 24B may include a probe feed actuator 96 connected to the probe 94 and secured to the support bracket 82B of the probe assembly 92. The support bracket 82B thus supports the probe feed actuator 96. The probe feed actuator 96 of each processing tool 24B may be configured to move the probe 94 along the longitudinal axis 68 between a retracted position and an extended position. That is, the probe 94 can be moved toward or away from the workpiece 12 via the probe feed actuator 96 depending on the stage of formation of the hole 52. The controller 36 is in communication with the probe feed actuator 96 of each processing tool 24B and controls the movement of the respective probe 94 along the longitudinal axis 68. The probe feed actuator 96 of a processing tool 24B may have any suitable configuration, and non-limiting examples of the probe feed actuator 96 may include a mechanical actuator, a pneumatic actuator, a hydraulic actuator, an electric actuator, a motor, or other suitable mechanism.

[0096] 11 and 16, the probe assembly 92 of each second processing tool 24B may include a probe feed bracket 98 connected to the probe 94 for moving the probe 94 relative to the workpiece 12. The probe feed bracket 98 may thus move the probe 94 between a retracted position and an extended position.

[0097] The probe feed bracket 98 is also connected to a probe feed actuator 96, which allows the probe feed bracket 98 and the probe 94 to move simultaneously with respect to one another via the probe feed actuator 96. The probe feed bracket 98 of the processing tool 24B thus supports the probe 94. The probe feed actuator 96 of each processing tool 24B is configured to move the probe feed bracket 98 and the probe 94 between a retracted position and an extended position.

[0098] 11 , the probe assembly 92 of each second processing tool 24B may include a first sensor 100 connected to the probe 94 for measuring the depth of the hole 52. The first sensor 100 of each second processing tool 24B is fixed to the support bracket 82B. Thus, the support bracket 82B supports the first sensor 100.

[0099] Additionally, the probe assembly 92 of each second process tool 24B may include a probe cap 102 attached to the probe 94 such that the probe cap 102 moves with the probe 94 between a retracted position and an extended position. The probe cap 102 is configured to provide a repeatable surface for making measurements. The first sensor 100 of the probe assembly 92 of each second process tool 24B is configured to measure the depth of the hole 52 based on the position of the repeatable surface of the probe cap 102.

[0100] The probe cap 102 of each second processing tool 24B may include a finger 104 connected to a first sensor 100. The finger 104 may include a repeatable surface. The first sensor 100 collects data from the position of the repeatable surface of the finger 104 relative to the first sensor 100. Furthermore, the first sensor 100 of each second processing tool 24B may include a rod 106 connected to the finger 104, such that movement of the finger 104 causes movement of the rod 106, thereby allowing the first sensor 100 to collect the distance the finger 104 moves on the rod 106.

[0101] 12A and 12B, the probe 94 of each second processing tool 24B may have a channel 108 and one or more outlets 110 in fluid communication with the channel 108. The channel 108 and outlets 110 of the probe 94 allow fluid communication through the probe 94 to the outside.

[0102] The probe assembly 92 of each processing tool 24B may include a pressure gauge 112 assembly that may be implemented to provide and / or determine measurements of the workpiece 12. Generally, the pressure gauge 112 assembly may be in communication with the controller 36.

[0103] The pressure gauge 112 assembly may include a pump 48B, e.g., a gas pump, in fluid communication with the probe 94 to supply a gaseous fluid, such as air or other suitable gaseous fluid, to the channel 108 and out through the outlet 110 of the probe 94. The controller 36 may be in communication with the pump 48B to control its operation, thereby selectively supplying or terminating the supply of gaseous fluid through the probe 94. The depth of the hole 52 and the depth of the countersink 54 may be determined using information from the airflow through the probe 94, as described in more detail below with reference to FIGS. 12A and 12B. Note that in some configurations, a single pump 48A may be implemented to control both the suction of the holder 42 and the pressure gauge 112. In this configuration, valves may be implemented to selectively direct fluid to desired locations. In other configurations, pumps 48A and 48B may be implemented to separately control the suction of holder 42 and pressure gauge 112, respectively.

[0104] Optionally, the hole 52 in the workpiece 12 may further include a countersink 54, in which case a second sensor 114 (see FIG. 11 ) may be implemented to measure the depth of the countersink 54. The pressure gauge 112 assembly may include the first sensor 100 and the second sensor 114.

[0105] In some configurations, as shown in FIG. 12B, each hole 52 can include a countersink portion 116 and a second portion 118. Generally, the countersink portion 116 and the second portion 118 of each hole 52 have different outer diameters. For example, the outer diameter of the second portion 118 is smaller than the outer diameter of the countersink portion 116. That is, the countersink portion 116 can taper toward the second portion 118, as best shown in FIG. 12B.

[0106] The probe assembly 92 of each second process tool 24B may include a second sensor 114 connected to the probe 94 for measuring the depth of the countersink 116 of the hole 52. The second sensor 114 of each second process tool 24B may measure the depth of the countersink 54 of the hole 52 by measuring the distance between the probe 94 and a surface reference for that probe 94 and comparing that measurement to a known, calibrated reference value for the hole 52.

[0107] The first sensor 100 and second sensor 114 of each processing tool 24B can communicate with the controller 36, which can collect and analyze data to determine whether the measurements, including depth measurements, are within predetermined tolerances for the holes 52 and countersinks 54.

[0108] The operation of probe 94 and pump 48B will be described with reference to Figures 12A and 12B. Probe 94 moves from a retracted position to an extended position by actuation of probe feed actuator 96, as shown by arrow A in Figure 12A. In this position, if bore 52 has a countersink 54, probe 94 is fully seated in countersink 54, as shown in Figure 12A. With probe 94 in the extended position, when pump 48B is activated via controller 36, gas fluid is pumped through probe 94 and out outlet 110. As shown in Figure 12A, outlet 110 is located outside bore 52, resulting in unrestricted airflow (i.e., high flow rate) and a low pressure reading (i.e., low backpressure). The first measurement value Z is determined as the distance between the state where the probe 94 is fully retracted and the state where the air flow (the flow caused by operating the pump 48B to pump the gas fluid out through the outlet 110 of the probe 94) is first restricted through the hole 52 as the probe 94 retracts through the hole 52.

[0109] The depth of hole 52 is determined based on the known length L of tip 120 of probe 94 minus first measurement Z (see FIG. 12A). First sensor 100 can measure the position of probe 94, and controller 36 can calculate or measure the depth of hole 52 by measuring where the air pressure and air flow change.

[0110] Next, while the airflow continues (airflow indicated by arrow F in FIG. 12B ), the controller 36 activates the probe feed actuator 96 to retract the probe 94 to the retracted position (see arrow B in FIG. 12B ), which moves the outlet 110 of the probe 94 into the interior of the bore 52. This condition causes the airflow to become restricted (i.e., the flow rate is reduced or decreased compared to unrestricted airflow), resulting in a higher pressure reading compared to the previous pressure reading measured outside the bore 52 (i.e., a higher back pressure compared to unrestricted airflow) because the outlet 110 has moved into the interior of the bore 52.

[0111] This high pressure reading can provide diameter information for the hole 52 by determining the distance the probe 94 travels through the hole 52. For example, if the air pressure exceeds a threshold as the probe 94 travels through the hole 52, this may indicate an anomaly in the hole 51 and / or a problem with the quality of the hole.

[0112] Once the probe 94 exits the bore 52, the controller 36 stops the pump 48B, stopping the flow of fluid through the probe 94. The controller 36 also stops the probe feed actuator 96, stopping the movement of the probe 94 to the retracted position.

[0113] The alignment of one or more of the processing tools 24A, 24B, 24C, and 24D may require fine adjustment. Accordingly, with reference to Figures 14A, 14B, and 15A-15B, the processing tool 24B may include a self-aligning compliance assembly 122 configured to flex the measurement device 90 and allow it to be positioned as desired so that it can measure various characteristics of the workpiece 12. More specifically, the probe assembly 92 of each second processing tool 24B includes a self-aligning compliance assembly 122 connected to the probe 94, which allows the probe 94 to flex relative to the workpiece 12 and accommodate one or more tolerances of the workpiece 12 as the probe 94 enters or is inserted into the hole 52. Generally, the self-aligning compliance assembly 122 of each processing tool 24B provides a passive compliance function.

[0114] 14A and 14B, the self-aligning compliance assembly 122 of the probe assembly 92 of each second processing tool 24B may include a housing 124 defining a cavity 126 along the longitudinal axis 68, with the probe 94 disposed through the cavity 126. The housing 124 is secured to the probe feed bracket 98 such that the housing 124 moves simultaneously with the probe feed bracket 98. Additionally, the tip 120 of the probe 94 extends outside the housing 124 (see FIGS. 11 and 16).

[0115] 15A and 15B, the self-aligning compliance assembly 122 of the processing tool 24B may include features that allow the probe 94 to move relative to the probe feed bracket 98, which in turn allows movement relative to the housing. More specifically, the self-aligning compliance assembly 122 of the processing tool 24B may implement reaction surfaces 128A, 128B and one or more biasers 130, 140 that cooperate with each other to independently move the probe 94 relative to the probe feed bracket 98, thereby providing passive self-alignment of the probe 94 with the bore 52, as described in more detail below.

[0116] 14A and 14B, the self-aligning compliance assembly 122 of the probe assembly 92 of each second processing tool 24B includes a first biasing member 130 disposed between a plurality of first reaction surfaces 128A within the housing 124, allowing the probe 94 to tilt relative to the longitudinal axis 68, thereby allowing the probe 94 to self-align with the workpiece 12 when inserted into the hole 52. Generally, as best shown in FIG. 15B, the first biasing member 130 is disposed between a pair of first reaction surfaces 128A, such that the first biasing member 130 repels each of the first reaction surfaces 128A.

[0117] As shown in FIG. 15A , the first reactive surface 128A and the first biasing member 130 are disposed within the cavity 126 of the housing 124. The first biasing member 130 is spring-biased and applies a biasing force to the probe 94 toward the initial position, thereby substantially aligning the probe 94 along the longitudinal axis 68 (see FIG. 15A ). In some configurations, when the probe 94 is in the initial position, the probe 94 may be concentric or coaxial with the longitudinal axis 68. Furthermore, the first biasing member 130 continuously biases the probe 94 outward, such that the tip 120 of the probe 94 is exposed outside the housing 124 when in the initial position.

[0118] 15A , in some configurations, the self-aligning compliance assembly 122 can include a first ledge 132 attached or secured to the probe 94. The first ledge 132 includes one of the first reaction surfaces 128A. Thus, the first biasing member 130 biases against the first ledge 132.

[0119] Additionally, the self-aligning compliance assembly 122 can include a second ledge 134 attached or secured to the housing 124 within the cavity 126. The second ledge 134 includes the other of the first reaction surfaces 128A. Thus, the first biasing member 130 biases against the second ledge 134.

[0120] In some configurations, the first ledge 132 and the second ledge 134 are aligned and spaced apart from one another, with their respective first reaction surfaces 128A facing one another. Thus, the first biasing member 130 is disposed between the first ledge 132 and the second ledge 134 and repels the respective first reaction surfaces 128A, continuously biasing the probe 94 toward the initial position.

[0121] 15A, the second ledge 134 defines an opening 136 having a boundary larger than the outer diameter of the probe 94, forming a gap 138 between the probe 94 and the second ledge 134. This allows the probe 94 to tilt within the opening 136 (see FIG. 15B).

[0122] 14A and 14B, in some configurations, the probe feed bracket 98 of the probe assembly 92 of the second processing tool 24B can include a plurality of spaced-apart second reactive surfaces 128B. Additionally, the self-aligning compliance assembly 122 of each probe assembly 92 of the second processing tool 24B can include a plurality of second biasing members 140. The second reactive surfaces 128B and the second biasing members 140 can independently move the housing 124 relative to the probe feed bracket 98, thereby achieving passive self-alignment of the housing 124 relative to the work surface 14, as described in more detail below. The second biasing members 140 can be the same type of biaser 130, 140 as the first biasing member 130, or a different type of biaser 130, 140. The biasers 130, 140, i.e., the first biasing member 130 and the second biasing member 140, may have any suitable configuration, non-limiting examples of which include coil springs, leaf springs, rubber contacts, elastomers, air cushions, expandable bladders, magnets, pneumatic mechanisms, and the like, or combinations thereof.

[0123] Generally, as best shown in FIG. 14B , at least one of the second biasing members 140 is disposed between a pair of second reaction surfaces 128B, and at least one other of the second biasing members 140 is disposed between the other pair of second reaction surfaces 128B. The second biasing members 140 are spring-loaded and continuously apply a biasing force that can return the probe 94 to its initial position, i.e., realign the probe 94 along the longitudinal axis 68. More specifically, the second biasing members can return the housing 124 to its initial position (the initial position of the housing 124 is shown in FIG. 15A ). In this manner, the second biasing members 140 react against their respective second reaction surfaces 128B to continuously bias the housing 124 toward its initial position.

[0124] 14A and 14B, in some configurations, the probe feed bracket 98 of each second processing tool 24B has one or more of the second reactive surfaces 128B, and the housing 124 of each second processing tool 24B has one or more other of the second reactive surfaces 128B. More specifically, in some configurations, the housing 124 of the probe assembly 92 of each second processing tool 24B can include a flange 142. This flange 142 can exhibit one or more of the second reactive surfaces 128B. 14B, the second biasing members 140 of the self-aligning compliance assemblies 122 of each second processing tool 24B are each disposed between a flange 142 (of the housing 124) and at least the other of the pair of second reaction surfaces 128B to compliantly accommodate the probe 94 relative to the workpiece 12, thereby allowing the housing 124 to self-align relative to the workpiece 12 when the probe 94 is inserted into the hole 52. In various configurations, the housing 124 may include multiple flanges 142, and each flange 142 may have one or more of the second reaction surfaces 128B.

[0125] 14B , in some configurations, the probe feed bracket 98 of the probe assembly 92 of each second processing tool 24B may include a plate 144 spaced from the flange 142, which may exhibit one or more of the second reaction surfaces 128B. Accordingly, the second biasing member 140 is disposed between the flange 142 and the plate 144, each of which has a second reaction surface 128B. The second biasing member 140 is spring-biased and may continuously apply a biasing force against the flange 142 and the plate 144 to return the housing 124 to its initial position and / or to return the probe 94 to its initial position and alignment along the longitudinal axis 68. In this manner, the second biasing member 140 reacts against the second reaction surface 128B of the flange 142 and the plate 144 to continuously bias the probe 94 toward its initial position.

[0126] The operation of the self-aligning compliance assembly 122 will be described with reference to Figures 15A-15B. Referring to Figure 15A, the probe feed actuator 96 is activated via the controller 36 to move the probe feed bracket 98, which correspondingly moves the probe 94 toward the workpiece 12. As shown in Figure 15A, the probe 94 moves in the direction of arrow A toward the workpiece 12, with the tip 120 of the probe 94 slightly misaligned with respect to the hole 52.

[0127] Next, as shown in FIG. 15B , when the tip 120 of the probe 94 contacts the hole 52, misalignment causes the probe 94 to tilt within the cavity 126 of the housing 124 via the self-aligning compliance assembly 122. Briefly referring to FIG. 14B , it is shown that tilting the probe 94 also causes the probe cap 102 to tilt. With continued reference to FIG. 15B , the housing 124 and the corresponding probe 94 move simultaneously, i.e., together, toward the workpiece 12. In response to misalignment, one or more of the first biasing member 130 and / or the second biasing member 140 can compress during insertion of the probe 94 into the hole 52 to aid in alignment of the probe 94 and minimize or avoid excessive external forces on the probe 94 due to misalignment. In some configurations, the first biasing member 130 aids in alignment of the probe 94, and the second biasing member 140 aids in alignment of the housing 124 relative to the work surface 14.

[0128] When the probe 94 is fully seated in the bore 52, the probe 94 self-aligns within the bore 52, thereby making the probe 94 concentric with the bore 52. Generally, when the probe 94 is fully seated in the bore 52, the various measurements described above can be performed. Optionally, other measurements can be performed while the probe 94 is in the bore 52. When the probe 94 is fully seated in the workpiece 12, the surface 146 of the housing 124 abuts the work surface 14 of the workpiece 12.

[0129] The housing 124 continues to move toward the workpiece 12 until the desired pressing force is reached, and if the face 146 of the housing 124 is not perpendicular to the work surface 14, the second biasing member 140 tilts the housing 124 so that the face 146 of the housing 124 is positioned perpendicular to the work surface 14. In other words, the second biasing member 140 causes the housing 124 to self-align with the work surface 14.

[0130] In yet another configuration of the processing tools 24A, 24B, 24C, 24D, each processing tool 24C may be an applicator configured to apply a material, compound, substance, or the like to the work surface 14.

[0131] Each of the processing tools 24A, 24B, 24C, 24D, for example, the third processing tool 24C, may include an applicator configured to apply a compound or the like to the work surface 14, thereby forming a pattern of the compound at a predetermined location in a processing region 38, such as the first processing region 38, the second processing region 38, or the third processing region 38.

[0132] For ease of explanation, the applicator will be referred to as the third processing tool 24C, however, in some situations, such as when the drill assembly 56 (first processing tool 24A described above) is not implemented and / or when the measurement device 90 (second processing tool 24B described above) is not implemented, the applicator may be referred to as the first processing tool 24A or the second processing tool 24B.

[0133] The applicator can be mounted to fixture 22 in a manner similar to that described above for the other processing tools 24A, 24B, 24C, 24D. For example, the applicator can include support brackets 82A, 82B attached to or secured to fixture 22 and / or fixture platform 26 for supporting the applicator.

[0134] The applicator may include a nozzle, a movable arm, a brush, a spray device, or other suitable feature capable of applying a material, compound, substance, etc. to the work surface 14. Additionally, the controller 36 may communicate with the applicator of each processing tool 24C and control the operation of the applicator. For example, the applicator may include an applicator actuator that ejects the material, compound, substance, etc. from a nozzle (if used) or moves a movable arm, etc., to apply the material, compound, substance, etc. to the work surface 14.

[0135] In some configurations, the applicator process may be performed before any other process described herein, in other configurations, the applicator process may be performed between other processes described herein, and in still other configurations, the applicator process may be performed after all processes described herein.

[0136] In another configuration of processing tools 24A, 24B, 24C, 24D, processing tool 24D may be an assembler configured to at least partially join multiple components 12 together. That is, the assembler may insert, attach, and / or apply a portion of an assembler element to one component 12, which is then attached to another component 12. Alternatively, two or more components 12 may be aligned and assembler elements may be inserted, attached, and / or applied to the components 12 together. Non-limiting examples of assembly processes may include mechanical joining, such as fasteners, clips, snaps, rivets, welded joining, adhesive joining, etc.

[0137] Each of the processing tools 24A, 24B, 24C, 24D, e.g., the fourth processing tool 24D, may include an assembler configured to at least partially join the parts 12 together, whereby the processing regions 38 form a pattern of assembled elements at predetermined locations. In some configurations, each processing tool 24D includes an assembler configured to insert fasteners into holes 52 in the work surface 14, whereby the processing region 38, such as the first processing region 38, the second processing region 38, the third processing region 38, or the fourth processing region 38, forms a pattern of fasteners disposed within the holes 52 at predetermined locations. Continuing with the fastener example, the fasteners can be assembled one by one, according to a pattern or sequence, and / or all at the same time.

[0138] For ease of explanation, the assembler will be referred to as the fourth processing tool 24D, however, in some situations, such as when the drill assembly 56 (first processing tool 24A described above) is not implemented, and / or when the measurement device 90 (second processing tool 24B described above) is not implemented, and / or when the applicator (third processing tool 24C described above) is not implemented, the assembler may be referred to as the first processing tool 24A, the second processing tool 24B, or the third processing tool 24C.

[0139] The assembler may be mounted to fixture 22 in a manner similar to that described above for the other processing tools 24A, 24B, 24C, 24D. For example, the assembler may include support brackets 82A, 82B attached to or secured to fixture 22 and / or fixture platform 26 for supporting the assembler.

[0140] The assembler may include a container containing fasteners, a drum containing fasteners, a movable arm, a fastener management system that supplies fasteners from a repository to the end effector tools 16A, 16B, 16C, or other suitable elements for performing an installation process on the work surface 14. Additionally, the controller 36 may communicate with and control the operation of the assembler of each process tool 24D.

[0141] In some configurations, the assembler process may be performed before any other processes described herein, in other configurations, the assembler process may be performed between other processes described herein, and in still other configurations, the assembler process may be performed after all processes described herein.

[0142] The present disclosure also provides a method for manufacturing, for example, an aircraft part 12. As shown in FIG. 1, a workpiece 12 is provided. As noted above, the workpiece 12 may be of any suitable configuration, and FIG. 1 is shown for illustrative purposes. FIG. 1 may also show any of processing tools 24A, 24B, 24C, and 24D attached to end effector tools 16A, 16B, and 16C. Thus, depending on the desired part 12 and / or the desired manufacturing process, the corresponding end effector tool 16A, 16B, and 16C is selected. As noted above, the workpiece 12 has a work surface 14 to be worked on.

[0143] An end effector tool 16A, 16B, 16C is selected to perform a task on the work surface 14. The selected end effector tool 16A, 16B, 16C is attached to a machine 18 for controlling the end effector tool 16A, 16B, 16C.

[0144] The end effector tools 16A, 16B, 16C are selected based on the desired process or operation to be performed on the work surface 14. As described above, many different examples of processing tools 24A, 24B, 24C, 24D have been described, and one of the processing tools 24A, 24B, 24C, 24D may be attached to each of the end effector tools 16A, 16B, 16C, or a combination of two or more of the processing tools 24A, 24B, 24C, 24D may be attached to each of the end effector tools 16A, 16B, 16C.

[0145] Thus, in some configurations, the end effector tools 16A, 16B, and 16C can be further defined as a first end effector tool 16A having a first processing tool 24A configured to perform a first operation on the work surface 14, and the first end effector tool 16A can be selected to perform a desired manufacturing process. Additionally, in some configurations, a second end effector tool 16B having, for example, a set of second processing tools 24B can be configured to perform a second operation on the work surface 14, and the second end effector tool 16B can be selected to perform a desired manufacturing process. This procedure can be repeated for different processing tools 24A, 24B, 24C, and 24D, and for as many manufacturing processes as possible. Once the selected end effector tool 16A, 16B, and 16C has completed its operation, the first end effector tool 16A can be swapped with the second end effector tool 16B, for example, to perform the next selected operation on the work surface 14. This procedure is repeated in a similar manner for the different processing tools 24A, 24B, 24C, 24D and for as many manufacturing processes as are envisaged.

[0146] As described above, the set of first processing tools 24A, 24B, 24C, 24D are mounted in the fixture 22 in a predetermined pattern, with the first processing tools 24A, 24B, 24C, 24D configured to perform an operation, such as a first process, on the work surface 14. Similarly, the set of second processing tools 24A, 24B, 24C, 24D may be mounted in the same fixture 22 as the first processing tools 24A, 24B, 24C, 24D, or the second processing tools 24A, 24B, 24C, 24D may be mounted in a different fixture 22 in the predetermined pattern. Generally, as described above, the second processing tools 24A, 24B, 24C, 24D are configured to perform another process, such as a second process, on a different work surface 14 than the first processing tools 24A, 24B, 24C, 24D. When the end effector tool 16C includes both a set of first and second processing tools 24A, 24B, 24C, 24D, the second processing tools 24A, 24B, 24C, 24D can be mounted in the fixture 22 adjacent to the set of first processing tools 24A, 24B, 24C, 24D. Operation of the first processing tools 24A, 24B, 24C, 24D can be initiated prior to operation of the second processing tools 24A, 24B, 24C, 24D via the controller 36. In other steps, the controller 36 can simultaneously control both the first processing tools 24A, 24B, 24C, 24D and the second processing tools 24A, 24B, 24C, 24D to perform both operations simultaneously.

[0147] Once the desired end effector tools 16A, 16B, and 16C are selected (here, for drilling), the end effector tools 16A, 16B, and 16C are attached to the workpiece 12 via the holder 42. First, the controller 36 uses data from the position sensor 30 to position the end effector tools 16A, 16B, and 16C at the desired location and orientation, i.e., the desired area, relative to the work surface 14. Next, the controller 36 activates the vacuum assembly 46. This causes the holder 42 to secure the selected end effector tool 16A, 16B, and 16C in a predetermined position on the workpiece 12 so that the work can be performed. For example, the vacuum assembly 46 is activated via the controller 36 to generate a suction force between the holder 42 and the workpiece 12, thereby vacuum-attaching the end effector tools 16A, 16B, and 16C to the predetermined position on the workpiece 12. Generally, the vacuum assembly 46 is activated prior to commencing operation of the first processing tool 24A, 24B, 24C, 24D.

[0148] Additionally, the controller 36 is configured to control the end effector tools 16A, 16B, and 16C, including controlling the processing tools 24A, 24B, 24C, and 24D. For example, the movement of the end effector tools 16A, 16B, and 16C is controlled via the controller 36 to position the first processing tools 24A, 24B, 24C, and 24D relative to the work surface 14 such that a predetermined pattern is aligned at a predetermined position on the work surface 14. Additionally, the operation of the first processing tools 24A, 24B, 24C, and 24D is controlled via the controller 36 to cause the first processing tools 24A, 24B, 24C, and 24D to perform an operation on the work surface 14 and form a first processing region 38 at a predetermined position on the work surface 14. Generally, operation of the processing tools 24A, 24B, 24C, 24D is performed after aligning and securing the end effector tools 16A, 16B, 16C relative to the work surface 14.

[0149] The controller 36 can control the processing tools 24A, 24B, 24C, and 24D as needed. In some configurations, the control of the operation of the first processing tool 24A (or any of the other processing tools 24B, 24C, and 24D, i.e., the second processing tool 24B, the third processing tool 24C, and the fourth processing tool 24D, etc.) is simultaneous. That is, all of the first processing tools 24A, 24B, 24C, and 24D can be operated simultaneously. Optionally, the control of the operation of the first processing tool 24A (or any of the other processing tools 24B, 24C, and 24D, i.e., the second processing tool 24B, the third processing tool 24C, and the fourth processing tool 24D, etc.) can be performed one at a time or according to a sequence or pattern, for example. The controller 36 can be programmed with programs and data for controlling and operating the end effector tools 16A, 16B, 16C and the corresponding processing tools 24A, 24B, 24C, 24D.

[0150] An example selection of several processing tools 24A, 24B, 24C, 24D is described below, although it should be noted that many other processes and combinations are possible, as discussed above. As discussed above, in some configurations, the first processing tool 24A may include a drill assembly 56 configured to form holes 52 in the work surface 14, thereby forming the first processing region 38 with a pattern of holes 52 at predetermined locations. Details of the drill assembly 56 have already been described, so please see above for further details.

[0151] Once the fixture 22 is attached to the workpiece 12 via the holder 42, the drilling process can begin. The clamp actuator 74 of each processing tool 24A can be activated via the controller 36, which moves the clamp 72 into engagement with the workpiece 12, causing the clamp 72 of each processing tool 24A to apply a predetermined force or pressure against the workpiece 12 to achieve a locked position. Once the clamp 72 of the processing tool 24A is in the locked position, the drill assembly 56, and more specifically the drill 58, of each first processing tool 24A can be activated (if necessary) via the controller 36 to form the hole 52 in the work surface 14. Once the drilling process is complete, the drill 58 of each processing tool 24A can be deactivated (if necessary) via the controller 36. If the end effector tools 16A, 16B, 16C include only the drill assembly 56, the controller 36 deactivates the vacuum assembly 46, releasing suction, which causes the holder 42 to release the end effector tools 16A, 16B, 16C from the workpiece 12. Alternatively, if the end effector tools 16A, 16B, 16C include only the drill assembly 56, the machine 18 can repeat the process for another location on the workpiece 12 or begin the process again for another workpiece 12.

[0152] If it is desired to perform other processing at the location where the hole has been drilled, the first end effector tool 16A (with the drill assembly 56) can be removed from the machine 18 and a second end effector tool 16B (with other processing tools 24A, 24B, 24C, 24D, e.g., second processing tool 24B) can be installed. Alternatively, the end effector tool 16C can include both the drill assembly 56 and other processing tools 24A, 24B, 24C, 24D, e.g., second processing tool 24B.

[0153] As mentioned above, in some configurations, each second processing tool 24B can include a probe assembly 92 configured to measure characteristics of the workpiece 12. For example, the probe assembly 92 can measure characteristics of the drilled hole 52 in the workpiece 12. As such, the probe assembly 92 is generally activated after the drilling process. Details of the probe assembly 92 have already been described, so please see above for further details.

[0154] Once the desired end effector tools 16A, 16B, 16C are selected (here, for a measurement process), the end effector tools 16A, 16B, 16C are attached to the workpiece 12 via the holder 42. First, the controller 36 uses data from the position sensor 30 to position the end effector tools 16A, 16B, 16C at the desired location and orientation, i.e., the desired area, relative to the work surface 14. Next, the controller 36 activates the vacuum assembly 46. This causes the holder 42 to secure the selected end effector tool 16A, 16B, 16C in a predetermined position on the workpiece 12 so that the work can be performed. For example, the vacuum assembly 46 is activated via the controller 36 to generate a suction force between the holder 42 and the workpiece 12, thereby vacuum-attaching the end effector tools 16A, 16B, 16C to the predetermined position on the workpiece 12. Generally, the vacuum assembly 46 is activated before the second process tool 24B is activated.

[0155] Additionally, the controller 36 is configured to control the end effector tools 16A, 16B, and 16C, including controlling the processing tools 24A, 24B, 24C, and 24D. For example, movement of the end effector tools 16A, 16B, and 16C is controlled via the controller 36, thereby positioning the second processing tool 24A, 24B, 24C, and 24D relative to the work surface 14 so that a predetermined pattern is aligned at a predetermined position relative to the work surface 14. Furthermore, operation of the second processing tool 24B is controlled via the controller 36, thereby causing the second processing tool 24B to perform an operation (a second operation) on the work surface 14 and further form a first processing region 38 or form a second processing region 38 at a predetermined position on the work surface 14. Generally, operation of the processing tools 24A, 24B, 24C, and 24D is performed after aligning and securing the end effector tools 16A, 16B, and 16C relative to the work surface 14.

[0156] The controller 36 can control the processing tools 24A, 24B, 24C, and 24D as needed. In some configurations, the control of the movement of the second processing tool 24B (or any of the other processing tools 24A, 24C, and 24D, i.e., the first processing tool 24A, the third processing tool 24C, and the fourth processing tool 24D, etc.) is simultaneous. That is, all of the second processing tools 24B can be operated simultaneously. Optionally, the control of the movement of the second processing tool 24B (or any of the other processing tools 24A, 24C, and 24D, i.e., the first processing tool 24A, the third processing tool 24C, and the fourth processing tool 24D, etc.) can be performed one at a time or according to a sequence or pattern, for example. The controller 36 can be programmed with programs and data for controlling and operating the end effector tools 16A, 16B, and 16C and the corresponding processing tools 24A, 24B, 24C, and 24D.

[0157] An example selection of several processing tools 24A, 24B, 24C, 24D is described below, although it should be noted that many other processes and combinations are possible, as discussed above. As discussed above, in some configurations, the second processing tool 24B may include a measurement device 90 configured to measure properties of the workpiece 12 at a predetermined location. Details of the measurement device 90 have already been described, so please see above for further details.

[0158] Once the fixture 22 is attached to the workpiece 12 via the holder 42, the measurement process can begin. The probe assembly 92 of each second processing tool 24B can be activated to measure characteristics of the workpiece 12. For example, the probe 94 of the probe assembly 92 can be moved into the hole 52 in the work surface 14 to measure the characteristics of the hole 52. More specifically, the controller 36 can activate the probe feed actuator 96 of each processing tool 24B to move the probe feed bracket 98, thereby moving the probe 94 into the hole 52 and moving the housing 124 toward the workpiece 12. Once the surface 146 of the housing 124 abuts the work surface 14 with a predetermined force or pressure and the probe 94 is fully seated within the hole 52, the measurement process begins and the controller 36 can collect and analyze data from the probe 94. The probe 94 may move as data is collected. That is, the controller 36 can continue to collect data even while the probe 94 is moving relative to the hole 52. Once the measurement process is complete, the probe 94 and housing 124 of each process tool 24B can be retracted via the controller 36. If the end effector tools 16A, 16B, 16C include only the probe assembly 92, the controller 36 can deactivate the vacuum assembly 46, releasing suction, which causes the holder 42 to release the end effector tools 16A, 16B, 16C from the workpiece 12. Alternatively, if the end effector tools 16A, 16B, 16C include only the probe assembly 92, the machine 18 can repeat the process for another location on the workpiece 12 or start the process again for another workpiece 12.

[0159] If it is desired to perform other processes at the location where the drilling and measurements have been performed, the end effector tool 16A, 16B, 16C (including the drill assembly 56 and probe assembly 92, or only the probe assembly 92) can be removed from the machine 18 and a third end effector tool 16A, 16B, 16C (including other process tools 24A, 24B, 24C, 24D, e.g., the third process tool 24C or the fourth process tool 24D) can be installed. Alternatively, the end effector tool 16A, 16B, 16C can include the drill assembly 56, the probe assembly 92, and other process tools 24A, 24B, 24C, 24D, e.g., the third process tool 24C and the fourth process tool 24D.

[0160] FIG. 17 illustrates another general example for manufacturing the part 12 described above. First, in block AA, the workpiece 12 is loaded into the work area. Next, in block BB, the controller 36 controls the machine 18 to select the desired end effector tools 16A, 16B, and 16C to perform the desired process, and then controls the processing tools 24A, 24B, 24C, and 24D to perform the selected desired process. Once these processes are completed in block CC, the controller 36 controls the machine 18 to perform an assembly process on the workpiece 12 and collect fastening data about the workpiece 12. The fastening data is collected, for example, during fastener insertion and fastening operations and may include, but is not limited to, data such as insertion force, insertion depth, fastening torque, fastener diameter, fastener identification, and fastener length. Then, once the assembly process and data entry process are complete, in block DD, the automated process is complete, and the machine 18 repeats the process for another workpiece 12. Thus, in block EE, the workpiece 12 is removed from the work area.

[0161] 18A and 18B show a more specific example for manufacturing the part 12 described above. First, in block AAA, the workpiece 12 is loaded into the work area. In block BBB, the controller 36 loads a program corresponding to the manufacturing process to be performed by the machine 18. In block CCC, the controller 36 controls the machine 18 to select and attach the desired end effector tool 16A, 16B, or 16C to the machine 18. In block DDD, the controller 36 connects to various programs and / or modules associated with the controlled structure for the selected processing tool 24A, 24B, 24C, or 24D. In block EEE, the controller 36 commands the machine 18 to move to a start position, i.e., a resynchronization position. The start position or resynchronization position is the position to which the machine 18 moves when collecting position information for the workpiece 12. In other words, the start position or resynchronization position is a reference collection position for automated equipment such as the machine 18. In block FFF, the controller 36, via the position sensor 30, measures or identifies one or more features about the workpiece 12 or the end effector tools 16A, 16B, 16C to determine the position and orientation of the workpiece 12. In block GGG, the controller 36 calculates and applies the positional and / or orientation (i.e., angular) offsets of the end effector tools 16A, 16B, 16C to command the machine 18 to position the end effector tools 16A, 16B, 16C in desired positions relative to the work surface 14. In block HHH, the controller 36 commands the machine 18 to move to a parked position to await the first operation. In block III, the controller 36 commands the machine 18 to adjust or correct the orientation of the processing tools 24A, 24B, 24C, 24D to position the processing tools 24A, 24B, 24C, 24D laterally or vertically relative to the workpiece 12 or work surface 14. The controller 36 uses data from a position sensor 30, such as a distance sensor, to position the end effector tools 16A, 16B, 16C in a desired position, orientation, or area relative to the work surface 14.

[0162] At block JJJ, once the end effector tools 16A, 16B, 16C are aligned in the desired position relative to the workpiece 12, the controller 36 activates the vacuum assembly 46. This causes the holder 42 to secure the selected end effector tool 16A, 16B, 16C in place on the workpiece 12 so that work can be performed. At block KKK, the controller 36 changes mode to force mode to provide flexibility. In force mode, the machine 18 may move in a programmed direction until a predetermined force is applied to a selected structure, and will stop moving when the force indicates that the desired flexibility has been achieved. For example, in force mode, the machine 18 moves the end effector tools 16A, 16B, 16C against the workpiece 12 until a predetermined force is applied by the end effector tools 16A, 16B, 16C against the workpiece 12, and stops moving the end effector tools 16A, 16B, 16C when this force indicates that a desired flexibility has been achieved between the workpiece 12 and the end effector tools 16A, 16B, 16C. Next, in block LLL, the controller 36 determines whether the holder 42 is applying the desired holding force against the workpiece 12. If yes, the method proceeds to block MMM. If no, the method proceeds to block NNN.

[0163] If the determination at block LLL is "No," the method proceeds to block NNN, where the controller 36 changes mode to a positioning mode so that the machine 18 can reposition the end effector tools 16A, 16B, and 16C. Thereafter, at block OOO, the controller 36 stops operation of the vacuum assembly 46 so that the holder 42 is released from the workpiece 12. At block PPP, the controller 36 calculates and applies offsets for the end effector tools 16A, 16B, and 16C and commands the machine 18 to reposition the end effector tools 16A, 16B, and 16C to the desired positions relative to the work surface 14. Blocks JJJ, KKK, and LLL are then repeated until the determination at block LLL is "Yes."

[0164] If the determination at block LLL is "yes," the method proceeds to blocks MMM and QQQ. At block MMM, the controller 36 activates the processing tools 24A, 24B, 24C, and 24D, which for purposes of illustration, in this example, activates the drill 58. At block QQQ, the controller 36 monitors the drilling process using sensors 62, such as vibration sensors, distance sensors, and / or flow sensors.

[0165] At block RRR, the controller 36 stops operation of the processing tools 24A, 24B, 24C, 24D, in this example, the drill 58. At block SSS, the drilling process is completed.

[0166] Returning to block QQQ, after this block, the controller 36 evaluates the desired measurements of the holes 52 in block TTT to determine whether the measurements are acceptable. The controller 36 may evaluate each hole 52 individually or may evaluate multiple holes 52 in parallel, i.e., simultaneously. If "Yes," the method proceeds to block SSS, where processing of the drill 58 is completed. If "No," processing of the method proceeds to block UUU, where the controller 36 stops operation of the vacuum assembly 46, allowing the holder 42 to be released from the workpiece 12. Thereafter, in block VVV, the controller 36 commands the machine 18 to move to a parked position to enable laser scanning of the workpiece 12. Optionally, a separate machine may be implemented to perform the laser scanning. Alternatively, the end effector tools 16A, 16B, 16C may include one or more lasers for performing laser scanning of the workpiece 12, such as laser scanning of each hole 52. Next, in block WWW, the controller 36 activates one or more laser scanners, and more specifically, activates one or more lasers of the laser scanners, to perform a laser scan of the drilled hole 52. The laser scanners perform a three-dimensional scan of the workpiece 12, and more specifically, the hole 52, to collect data that can be used to determine the quality of the hole 52, such as the angle of the hole 52 and the depth of the countersink 54.

[0167] Continuing with reference to block WWW, because the holder 42 is not fixed relative to the workpiece 12, the end effector tools 16A, 16B, 16C are not fixed relative to the workpiece 12 when the laser scanning is performed. The method then returns to block SSS, where processing of the drill 58 is completed.

[0168] Once the first operation is complete, in this example, a drilling operation, the method proceeds to block XXX. In block XXX, the controller 36 commands the machine 18 to move to a standby position to await the second operation. For ease of explanation, the second operation is shown as a measurement operation. Also in block XXX, the controller 36 calculates and applies the positional offset of the end effector tools 16A, 16B, 16C from the drilling operation and commands the machine 18 to position the end effector tools 16A, 16B, 16C in the desired position relative to the work surface 14. In block YYY, once the end effector tools 16A, 16B, 16C are aligned in the desired position relative to the workpiece 12, the controller 36 activates the vacuum assembly 46. This causes the holder 42 to secure the selected end effector tool 16A, 16B, 16C in place on the workpiece 12 so that the next operation can be performed.

[0169] In block ZZZ, the controller 36 changes the mode to force mode to provide flexibility. As described above, in force mode, the machine 18 may move in a programmed direction until a predetermined force is applied to a selected structure, and will stop moving when this force indicates that the desired flexibility has been achieved (see above for details). Next, in block ABB, the controller 36 determines whether the holder 42 is exerting the desired holding force on the workpiece 12. If yes, the method proceeds to block ACC. If no, the method proceeds to block ADD.

[0170] If the determination in block ABB is "No," the method proceeds to block ADD, where the controller 36 changes mode to a positioning mode so that the machine 18 can reposition the end effector tools 16A, 16B, and 16C. Thereafter, in block AEE, the controller 36 stops operation of the vacuum assembly 46 so that the holder 42 is released from the workpiece 12. In block AFF, the controller 36 calculates and applies offsets for the end effector tools 16A, 16B, and 16C and commands the machine 18 to reposition the end effector tools 16A, 16B, and 16C to the desired positions relative to the work surface 14. Blocks YYY, ZZZ, and ABB are then repeated until the determination in block ABB is "Yes."

[0171] If the determination at block ABB is "yes," the method proceeds to block ACC, where the controller 36 activates the processing tools 24A, 24B, 24C, and 24D, and in this example, for purposes of illustration, activates a measuring device 90, such as a probe 94. In block AGG, the controller 36 determines whether the data from the measuring device 90, such as the probe 94, and therefore the results, are acceptable. That is, in block AGG, the controller 36 determines whether the depth of the hole 52 and / or the depth of the countersink 54 for the hole 52 are acceptable, whether the diameter of the hole 52 and / or the diameter of the countersink 54 for the hole 52 are acceptable, or other quality criteria for the workpiece 12. If "yes," the method proceeds to block AHH. If "no," the method proceeds to block AII.

[0172] If the determination in block AGG is "no," the method proceeds to block AII, where the controller 36 examines or analyzes the magnitude of the data collected from the measurement device 90, and therefore the results. Subsequently, further continuation of the method based on the determination in block AGG being "no," causes the controller 36 to select one of blocks AJJ, AKK, ALL, or AMM for execution. If block AJJ is selected, the next process is stopped, and in this example, for purposes of illustration, the controller 36 commands the machine 18 to stop the next drilling process. If block AKK is selected, the controller 36 commands the machine 18 to stop some of the processing tools 24A, 24B, 24C, and 24D, in this example, to stop some of the drills 58 in the next drilling process. If block ALL is selected, the controller 36 commands or makes one or more adjustments to one or more of the processing tools 24A, 24B, 24C, and 24D, in this example, to the drills 58 in the next drilling process. If block AMM is selected, the controller 36 commands the machine 18 to move to a parked position to enable laser scanning of the workpiece 12. With continued reference to block AMM, the controller 36 activates one or more lasers to perform laser scanning of the drilled holes 52. With continued reference to block AMM, because the holder 42 is not fixed relative to the workpiece 12, the end effector tools 16A, 16B, 16C are not fixed relative to the workpiece 12 when the laser scanning is performed.

[0173] If the determination result in block AGG is "yes," the method proceeds to block AHH, where the controller 36 stops operation of the processing tools 24A, 24B, 24C, and 24D, and in this example, stops operation of the probe 94. Next, in block ANN, the second process is completed, and in this example, the measurement process is completed. If additional processing is required, the method can then return to block HHH and repeat the processing from blocks HHH to ANN. Thus, in block ANN, a determination is made whether to return to block HHH or to proceed to block AOO. For example, if the controller 36 determines that repositioning of the end effector tools 16A, 16B, and 16C and / or the machine 18 is required, the method returns to block HHH. If in block ANN it is determined that additional processing is not required, the method proceeds to block AOO.

[0174] After block ANN, the method may proceed to block AOO, where the controller 36 determines that work for the area is complete. If additional processing is required, the method may then return to block EEE and repeat the processing from blocks EEE through AOO. Thus, in block AOO, a determination is made whether to return to block EEE or to proceed to block APP. For example, if the controller 36 determines that repositioning of the end effector tools 16A, 16B, 16C and / or the machine 18 is required, the method returns to block EEE. If it is determined in block AOO that no additional processing is required, the method proceeds to block APP.

[0175] After block AOO, the method may proceed to block APP, in which the controller 36 determines that the first and second processes are complete; in this example, the controller 36 determines that the drilling process and measurement process are complete.

[0176] It should be noted that the order or sequence of performing the method described above is exemplary, and other orders or sequences are within the scope of the present disclosure. Also, the method may include features other than those described above.

[0177] Although the best mode for carrying out the present disclosure and other configurations have been described in detail, those skilled in the art will recognize various alternative designs and configurations for carrying out the present disclosure within the scope of the appended claims. Furthermore, the features of the illustrated configurations or the various configurations described herein are not necessarily to be understood as independent configurations. Rather, each feature described in one example of a configuration may be combined with one or more other desired features obtained from other configurations, resulting in other configurations not shown in the description or drawings herein. Therefore, such other configurations are also encompassed within the scope of the appended claims.

[0178] As used herein, a system, device, structure, article, element, component, or hardware that is "configured" to perform a particular function refers to one that can perform that particular function without any modification, and not one that requires any modification to perform that particular function. That is, a system, device, structure, article, element, component, or hardware that is "configured" to perform a particular function refers to one that has been specifically selected, made, implemented, utilized, programmed, and / or designed to perform that particular function. As used herein, "configured" refers to a characteristic that a system, device, structure, article, element, component, or hardware already possesses, which characteristic enables the system, device, structure, article, element, component, or hardware to perform that particular function without any modification. In this disclosure, a system, device, structure, article, element, component, or hardware that is "configured" to perform a particular function may also or instead be described as being "adapted" and / or "operable" to perform that function.

[0179] The drawings illustrating the configurations described herein are intended to provide a general understanding of how the various configurations work. These drawings do not completely describe all of the elements and features of apparatus and systems that use the structures and methods described herein. Many other configurations will be apparent to those skilled in the art upon review of this disclosure. Other configurations may be utilized or derived from this disclosure, and structural and logical substitutions and modifications may be made without departing from the scope of the disclosure. Accordingly, the disclosure and the drawings should be considered illustrative, and not restrictive.

[0180] The following appendix provides exemplary configurations of the processing system 10, probe assembly 92, and methods of the present disclosure.

[0181] Appendix 1. A processing system for manufacturing a part, comprising: a workpiece having a work surface; an end effector tool; and a controller in communication with the end effector tool, the end effector tool comprising a fixture and a set of first processing tools attached to the fixture in a predetermined pattern, the first processing tools configured to perform an operation on the work surface; and the controller comprising a processor configured to execute instructions from a memory, whereby the controller controls movement of the end effector tool to position the first processing tool relative to the work surface so that the predetermined pattern is aligned at a predetermined position relative to the work surface; and controls operation of the first processing tool so that the first processing tool performs the operation on the work surface and forms a first processing area at the predetermined position on the work surface.

[0182] Appendix 2. The processing system of Appendix 1, wherein the work surface exhibits a first configuration, the fixture includes a fixture platform having an outer surface, the outer surface exhibiting a second configuration complementary to the first configuration, and a portion of each of the first processing tools is movable through the fixture platform when the operation is performed on the work surface.

[0183] Clause 3. The processing system of any one of the preceding clauses, wherein the controller is configured to simultaneously control operation of each of the first processing tools.

[0184] Clause 4. The processing system of any one of the preceding clauses, wherein when the end effector tool is positioned adjacent to the workpiece, the work surface of the workpiece and the outer surface of the fixture face each other, the workpiece is an aircraft panel, the first configuration of the work surface is arcuate with a convex and / or concave orientation, the second configuration of the outer surface of the fixture platform is arcuate with an opposite convex and / or concave orientation to the work surface, and the work surface and the fixture platform are in a complementary relationship.

[0185] Clause 5. The processing system of any one of the preceding clauses, wherein the end effector tool includes a coupler attached to the fixture.

[0186] Appendix 6. The processing system of any one of the preceding appendices, wherein the end effector tool is further defined as a first end effector tool having the first processing tool, and wherein the processing system further includes a second end effector tool having a set of second processing tools, the first processing tool configured to perform a first process on the work surface and the second processing tool configured to perform a second process on the work surface, and wherein the first end effector tool and the second end effector tool are interchangeable and perform different operations on the work surface.

[0187] Appendix 7. The processing system of Appendix 6, wherein each of the first processing tools includes a drill assembly configured to form holes in the work surface, whereby the first processing area forms a pattern of holes at the predetermined locations.

[0188] Clause 8. The processing system of clause 7, wherein the drill assembly of each of the first processing tools is configured to form a countersink aligned with the hole in the work surface.

[0189] Appendix 9. The processing system of Appendix 6, wherein each of the first processing tools includes an applicator configured to apply a compound to the work surface, whereby the first processing region forms a pattern of compound at the predetermined location.

[0190] Appendix 10. The processing system of Appendix 7 or 8, wherein each of the second processing tools includes an assembler configured to insert fasteners into the holes in the work surface, whereby the first processing area forms a pattern of fasteners disposed within the holes formed at the predetermined locations.

[0191] Clause 11. The processing system of clause 6, wherein each of the second processing tools includes a measurement device configured to measure a characteristic of the workpiece.

[0192] Clause 12. The processing system of clause 11, wherein the measurement device of each of the second processing tools includes a probe assembly configured to measure a characteristic of the workpiece.

[0193] Clause 13. The processing system of clause 12, wherein the probe assembly of each of the second processing tools includes a probe insertable into the hole in the work surface for measuring a characteristic of the hole.

[0194] Appendix 14. The processing system of any one of appendices 1 to 5, wherein the end effector tool includes a set of second processing tools mounted in the fixture proximate to the set of first processing tools, the first processing tools configured to perform a first process on the work surface, and the second processing tools configured to perform a second process on the work surface.

[0195] Appendix 15. The processing system of Appendix 14, wherein each of the first processing tools includes a drill assembly configured to form a hole in the work surface, and each of the second processing tools includes a measurement device configured to measure a characteristic of the workpiece.

[0196] Clause 16. The processing system of any one of the preceding clauses, wherein the end effector tool includes an end effector mounting assembly configured to contact the workpiece and secure the end effector tool in the predetermined position.

[0197] Appendix 17. The processing system of Appendix 16, wherein the end effector mounting assembly includes a plurality of holders attached to the fixture and a vacuum assembly in fluid communication with the holders, and the controller activates the vacuum assembly when the holders engage the workpiece, generating a suction force between the holders and the workpiece to vacuum-mount the end effector tool against the predetermined position on the workpiece.

[0198] Clause 18. The processing system of clause 17, wherein the holder is further defined as a suction cup.

[0199] Addendum 19. The processing system of any one of the preceding addenda, wherein the end effector tool includes a plurality of position sensors connected to the fixture, the position sensors configured to align the end effector tool with respect to the workpiece, thereby aligning the first processing tool to the predetermined position.

[0200] Clause 20. The processing system of clause 19, wherein the position sensor includes a camera assembly.

[0201] Addendum 21. The processing system of Addendum 19 or 20, wherein the workpiece includes at least one reference guide, and the position sensor is configured to identify the reference guide and position the end effector tool relative to the work surface, thereby aligning the first processing tool with the predetermined position.

[0202] Clause 22. The processing system of any one of the preceding clauses, wherein each of the first processing tools includes a drill assembly.

[0203] Clause 23. The processing system of clause 22, wherein the drill assembly of each of the first processing tools includes: a drill having a processing bit; a drill feed actuator connected to the drill and configured to move the processing bit along a longitudinal axis between a retracted position and an extended position; and a drill actuator connected to the processing bit and configured to selectively operate the processing bit.

[0204] Appendix 24. The processing system of Appendix 23, wherein the controller is configured to control operation of a drill of each of the first processing tools, the machining bits of the drills forming holes in the work surface and forming a pattern of holes at the predetermined locations.

[0205] Clause 25. The processing system of any one of the preceding clauses, wherein each of the first processing tools includes a probe assembly.

[0206] Clause 26. The processing system of clause 25, wherein the probe assembly of each of the first processing tools includes a probe configured to measure a characteristic of the workpiece.

[0207] Addendum 27. The processing system of Addendum 26, wherein the work surface of the workpiece defines a plurality of holes, and wherein the probes are insertable into respective ones of the plurality of holes in the work surface to measure characteristics of the holes.

[0208] Clause 28. The processing system of clause 27, wherein each probe assembly of the first processing tool includes a first sensor connected to the probe for measuring the depth of the hole.

[0209] Addendum 29. The processing system of Addendum 27 or 28, wherein the probe assembly of each of the first processing tools includes a probe cap attached to the probe, the probe cap moving with the probe between a retracted position and an extended position, and a first sensor of the probe assembly of each of the first processing tools configured to measure the depth of the hole based on the position of the probe cap.

[0210] Addendum 30. A processing system described in any one of Addendums 27 to 29, wherein each of the holes includes a countersunk portion and a second portion, the countersunk portion and the second portion each having a different outer diameter, and the probe assembly of each of the first processing tools includes a second sensor connected to the probe for measuring the depth of the countersunk portion of the hole.

[0211] Addendum 31. A processing system according to any one of Addendums 27 to 29, wherein each probe assembly of the first processing tool includes a self-aligning compliance assembly connected to the probe, which allows the probe to flexibly conform to the workpiece and accommodate one or more workpiece tolerances when the probe enters the hole.

[0212] Addendum 32. The processing system of Addendum 31, wherein the self-aligning compliance assembly of each probe assembly of the first processing tool includes a housing defining a cavity along a vertical axis, the probe being positioned through the cavity, and the self-aligning compliance assembly of each probe assembly of the first processing tool includes a first biasing member positioned between a plurality of first reaction surfaces within the housing, allowing the probe to tilt relative to the vertical axis, thereby self-aligning the probe with respect to the workpiece when inserted into the hole.

[0213] Addendum 33. The processing system of Addendum 32, wherein each probe assembly of the first processing tool includes a probe feed bracket connected to the probe and configured to move the probe between a retracted position and an extended position, the probe feed bracket of each probe assembly of the first processing tool includes a plurality of second reactive surfaces spaced apart from one another, the housing of each probe assembly of the first processing tool includes a flange presenting at least one of the second reactive surfaces, and the self-aligning compliance assembly of each probe assembly of the first processing tool includes a plurality of second biasing members, the second biasing member of the self-aligning compliance assembly of each first processing tool being positioned between the flange and at least one other of the pair of second reactive surfaces to enable the probe to flexibly respond to the workpiece, thereby enabling the probe to self-align with the workpiece when inserted into the hole.

[0214] Addendum 34. A probe assembly for measuring characteristics of a hole in a workpiece, comprising: a probe insertable into the hole in the workpiece to measure the characteristics of the hole; and a self-aligning compliance assembly connected to the probe, thereby enabling the probe to flexibly conform to the workpiece and to conform to one or more workpiece tolerances when the probe is inserted into the hole.

[0215] Addendum 35. The probe assembly of Addendum 34, wherein the self-aligning compliance assembly includes a housing defining a cavity along a longitudinal axis, the probe being positioned through the cavity, and the self-aligning compliance assembly includes a first biasing member disposed between a plurality of first reaction surfaces within the housing, allowing the probe to tilt relative to the longitudinal axis, thereby self-aligning the probe with respect to the workpiece when inserted into the hole.

[0216] Addendum 36. The probe assembly of Addendum 34 or 35, further comprising a probe feed bracket connected to the probe for moving the probe relative to the workpiece, the probe feed bracket including a plurality of second reaction surfaces spaced apart from one another, the housing including a flange presenting at least one of the second reaction surfaces, and the self-aligning compliance assembly including a plurality of second biasing members disposed between the flange and at least one other of the pair of second reaction surfaces, allowing the probe to flexibly respond to the workpiece, thereby allowing the probe to self-align with the workpiece when the probe is inserted into the hole.

[0217] Addendum 37. A method for manufacturing an aircraft part, comprising: providing a workpiece having a working surface; selecting an end effector tool to perform an operation on the work surface, the end effector tool including a fixture and a set of first processing tools mounted on the fixture in a predetermined pattern, the first processing tools configured to perform the operation on the work surface; controlling, via a controller, movement of the end effector tool to position the first processing tool relative to the work surface, whereby the predetermined pattern is aligned at a predetermined position relative to the work surface; and controlling, via the controller, operation of the first processing tool, whereby the first processing tool performs the operation on the work surface and forms a first processing area at the predetermined position on the work surface.

[0218] Clause 38. The method of clause 37, wherein the control of the operation of the first processing tool is simultaneous.

[0219] Addendum 39. The method of Addendum 37 or 38, wherein the end effector tool is further defined as a first end effector tool having the first processing tools configured to perform a first operation on the work surface, and further includes a second end effector tool having a set of second processing tools configured to perform a second operation on the work surface, the method further comprising interchanging the first end effector tool with the second end effector tool to perform the selected operation on the work surface.

[0220] Addendum 40. A method according to any one of Addendums 37-39, wherein each of the first processing tools includes a drill assembly configured to form holes in the work surface, whereby the first processing area forms a pattern of holes at the predetermined locations, and the method further comprises activating the drill assembly of each of the first processing tools to form holes in the work surface.

[0221] Addendum 41. A method according to any one of Addendums 37 to 40, wherein each of the second processing tools includes a probe assembly configured to measure a characteristic of the workpiece, and the method further comprises measuring the characteristic of the workpiece by activating the probe assembly of each of the second processing tools.

[0222] Clause 42. The method of clause 41, further comprising moving a probe of the probe assembly into the hole in the work surface to measure a characteristic of the hole.

[0223] Addendum 43. The method of Addendum 37 or 38, wherein the end effector tool includes a set of second processing tools mounted on the fixture adjacent to the set of first processing tools, the first processing tools configured to perform a first process on the work surface, and the second processing tools configured to perform a second process on the work surface, the method further comprising initiating operation of the second processing tools via the controller after initiating operation of the first processing tools.

[0224] Addendum 44. The method of any one of Addendums 37 to 43, further comprising attaching the end effector tool to the workpiece via a plurality of holders.

[0225] Addendum 45. The method of Addendum 44, further comprising activating a vacuum assembly via the controller to generate a suction force between the holder and the workpiece, thereby vacuum-attaching the end effector tool to the predetermined position on the workpiece.

[0226] Clause 46. The method of clause 45, wherein activation of the vacuum assembly occurs before initiating operation of the first processing tool.

Claims

1. 1. A processing system for manufacturing a part, comprising: a workpiece having a working surface; an end effector tool; a controller in communication with the end effector tool; The end effector tool includes a fixture; a set of first processing tools mounted on the fixture in a predetermined pattern, the first processing tools configured to perform operations on the work surface; The controller includes a processor configured to execute instructions from a memory, whereby the controller: controlling movement of the end effector tool to position the first processing tool relative to the work surface, thereby aligning the predetermined pattern at a predetermined position relative to the work surface; A processing system that controls operation of the first processing tool, whereby the first processing tool performs the operation on the work surface and forms a first processing area at the predetermined location on the work surface.

2. the work surface exhibits a first configuration; the fixture includes a fixture platform having an outer surface, the outer surface exhibiting a second configuration complementary to the first configuration; a portion of each of the first processing tools may move through the fixture platform when the operation is performed on the work surface; The processing system of claim 1 , wherein the controller is configured to simultaneously control the operation of each of the first processing tools.

3. when the end effector tool is positioned adjacent to the workpiece, the working surface of the workpiece and the outer surface of the fixture face each other; the workpiece is an aircraft panel, and the first configuration of the work surface is arcuate in a convex and / or concave orientation; 3. The processing system of claim 2, wherein the second configuration of the exterior surface of the fixture platform is arcuate in an opposite convex and / or concave orientation to the work surface, the work surface and the fixture platform being in a complementary relationship.

4. The processing system of claim 2 , wherein the end effector tool comprises a coupler attached to the fixture.

5. The end effector tool is further defined as a first end effector tool having the first processing tool; the processing system further includes a second end effector tool having a set of second processing tools; the first processing tool is configured to perform a first process on the work surface and the second processing tool is configured to perform a second process on the work surface; 10. The processing system of claim 1, wherein the first end effector tool and the second end effector tool are interchangeable to perform different operations on the work surface.

6. each of the first processing tools includes a drill assembly configured to drill holes in the work surface, whereby the first processing area forms a pattern of holes at the predetermined locations; The processing system of claim 5 , wherein the drill assembly of each of the first processing tools is configured to form a countersink aligned with the hole in the work surface.

7. 6. The processing system of claim 5, wherein each of the first processing tools includes an applicator configured to apply a compound to the work surface, whereby the first processing region forms a pattern of compound at the predetermined location.

8. 7. The processing system of claim 6, wherein each of the second processing tools includes an assembler configured to insert fasteners into the holes in the work surface, whereby the first processing region forms a pattern of fasteners disposed within the holes formed at the predetermined locations.

9. 7. The processing system of claim 5 or 6, wherein each of the second processing tools includes a measurement device configured to measure a property of the workpiece.

10. 10. The processing system of claim 9, wherein the measurement device of each of the second processing tools includes a probe assembly configured to measure a property of the workpiece.

11. 11. The processing system of claim 10, wherein the probe assembly of each of the second processing tools includes a probe insertable into the hole in the work surface for measuring a characteristic of the hole.

12. the end effector tool includes a set of second processing tools mounted in the fixture adjacent to the set of first processing tools; 10. The processing system of claim 1, wherein the first processing tool is configured to perform a first process on the work surface and the second processing tool is configured to perform a second process on the work surface.

13. each of the first processing tools includes a drill assembly configured to form a hole in the work surface; The processing system of claim 12 , wherein each of the second processing tools includes a measurement device configured to measure a property of the workpiece.

14. The processing system of claim 1 , wherein the end effector tool includes an end effector mounting assembly configured to contact the workpiece and secure the end effector tool in the predetermined position.

15. the end effector mounting assembly includes a plurality of holders mounted to the fixture and a vacuum assembly in fluid communication with the holders; the controller activates the vacuum assembly when the holder engages the workpiece, creating a suction force between the holder and the workpiece to vacuum-attach the end effector tool to the predetermined location on the workpiece; 15. The processing system of claim 14, wherein said holder is further defined as a suction cup.

16. the end effector tool includes a plurality of position sensors coupled to the fixture; the position sensor is configured to align the end effector tool with respect to the workpiece, thereby aligning the first processing tool with the predetermined position; The processing system of claim 1 , wherein the position sensor comprises a camera assembly.

17. the workpiece includes at least one reference guide; 17. The processing system of claim 16, wherein the position sensor is configured to identify the reference guide and position the end effector tool relative to the work surface, thereby aligning the first processing tool with the predetermined position.

18. each of the first processing tools includes a drill assembly; The drill assembly of each of the first processing tools comprises: a drill having a machining bit; a drill feed actuator connected to the drill and configured to move the drill bit along a longitudinal axis between a retracted position and an extended position; 10. The processing system of claim 1, further comprising: a drill actuator connected to the machine bit and configured to selectively operate the machine bit.

19. 20. The processing system of claim 18, wherein the controller is configured to control operation of a drill of each of the first processing tools, the machining bits of the drills forming holes in the work surface to form a pattern of holes at the predetermined locations.

20. each of the first processing tools includes a probe assembly; the probe assembly of each of the first processing tools includes a probe configured to measure a property of the workpiece; 10. The processing system of claim 1, wherein the work surface of the workpiece defines a plurality of holes, and wherein the probes are insertable into respective ones of the plurality of holes in the work surface to measure properties of the holes.

21. 21. The processing system of claim 20, wherein each probe assembly of the first processing tool includes a first sensor connected to the probe for measuring the depth of the hole.

22. each probe assembly of the first processing tool includes a probe cap attached to the probe, the probe cap moving with the probe between a retracted position and an extended position; 22. The processing system of claim 21, wherein a first sensor of a probe assembly of each of the first processing tools is configured to measure a depth of the hole based on a position of the probe cap.

23. each of the holes includes a countersink portion and a second portion, the countersink portion and the second portion having different outer diameters; 21. The processing system of claim 20, wherein each probe assembly of the first processing tool includes a second sensor connected to the probe for measuring the depth of the countersink of the hole.

24. 21. The processing system of claim 20, wherein each probe assembly of the first processing tool includes a self-aligning compliance assembly connected to the probe, which allows the probe to flexibly conform to the workpiece and accommodate one or more workpiece tolerances when the probe enters the hole.

25. the self-aligning compliance assembly of each probe assembly of the first processing tool includes a housing defining a cavity along a longitudinal axis, the probe being disposed through the cavity; 25. The processing system of claim 24, wherein the self-aligning compliance assembly of each probe assembly of the first processing tool includes a first biasing member disposed between a plurality of first reaction surfaces within the housing, allowing the probe to tilt relative to the longitudinal axis, thereby self-aligning the probe with the workpiece when inserted into the hole.

26. each probe assembly of the first processing tool includes a probe feed bracket connected to the probe and configured to move the probe between a retracted position and an extended position; a probe feed bracket of each probe assembly of the first processing tool including a plurality of second reaction surfaces spaced apart from one another; a housing of each probe assembly of the first processing tool includes a flange that presents at least one of the second reactive surfaces; the self-aligning compliance assembly of each probe assembly of the first processing tool includes a plurality of second biasing members; 26. The processing system of claim 25, wherein a second biasing member of a self-aligning compliance assembly of each of the first processing tools is disposed between the flange and at least the other of the pair of second reaction surfaces to enable the probe to flexibly conform to the workpiece, thereby enabling the probe to self-align with the workpiece when inserted into the hole.

27. 1. A method for manufacturing an aircraft component, comprising: providing a workpiece having a working surface; selecting an end effector tool to perform a task on the work surface, the end effector tool comprising: Fixtures and a set of first processing tools mounted on the fixture in a predetermined pattern, the first processing tools configured to perform the operations on the work surface; controlling, via a controller, movement of the end effector tool to position the first processing tool relative to the work surface, thereby aligning the predetermined pattern at a predetermined position relative to the work surface; and controlling operation of the first processing tool via the controller, whereby the first processing tool performs the operation on the work surface and forms a first processing area at the predetermined location on the work surface.

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