Tool-engagement coupling and related methods

Abstract

A tool-engaging coupler configured to deliver a tool to a work location on a workpiece, the tool-engaging coupler further being movable by a robot arm to engage a locator at the work location. The tool-engaging coupler includes an engagement member having a first predetermined shape adapted to engage a locator having a second predetermined shape. The tool-engaging coupler is adapted to be moved by the robot arm based on a level of spatial tolerance that decreases as the engagement member approaches the locator based at least in part on the first predetermined shape and the second predetermined shape.

Description

[Technical Field]

[0001] More particularly, the present invention relates to a tool engaging coupling and associated method configured to position a tool at a predetermined location on a workpiece. [Background technology]

[0002] Vehicle manufacturing traditionally requires skilled workers to work in unergonomic areas with limited access for extended periods of time using numerous different tools and shop aids to complete drilling tasks. Traditional methods involve a wide range of process variables that are difficult to quantify, such as the worker's skill and concentration level, the accuracy of drilling tool placement (e.g., blocks and bushings, drill jigs), and the maintainability of hand tools (e.g., air drills, drill bits, torque wrenches). All of these factors contribute to increased potential for NCRs / quality defects, variability in process completion time, and costs for air vehicle manufacturing.

[0003] Although various solutions have been proposed, they fail to address the problem, meaning that there remains a need to automate at least some of the actions currently performed by workers. Furthermore, a precise process is required to ensure that the tool is guided to a precise location to perform any given operation. Summary of the Invention

[0004] According to one aspect of the present invention, there is provided a tool-engaging coupler configured to deliver a tool to a work location on a workpiece, the tool-engaging coupler further being movable by a robotic arm to engage a locator at the work location, the tool-engaging coupler including an engaging member having a first predetermined shape adapted to engage a locator having a second predetermined shape, the tool-engaging coupler adapted to be moved by the robotic arm based on a level of spatial tolerance that decreases as the engaging member approaches the locator based at least in part on the first predetermined shape and the second predetermined shape.

[0005] Preferably, during movement of the tool-engaging coupler towards the working position, the tool-engaging coupler is compliant in multiple axes.

[0006] Preferably, movement of the tool engaging coupler is configured to be constrained against movement in one or more axes.

[0007] Preferably, the tool engagement coupler is movable in the z-axis by the robot arm as the engagement member approaches the locator.

[0008] Preferably, when the first and second predetermined features engage, movement of the tool engagement coupler is constrained in one or more axes.

[0009] Preferably, the tool engaging coupler is configured to be compliant in at least one of the x, y, z, pitch, roll, and yaw axes.

[0010] Preferably, the first predetermined shape and the second predetermined shape are configured to move the tool engagement coupler thereby moving the engagement member towards the working position.

[0011] Preferably, the first predetermined shape comprises a tapered shape at the distal end of the engagement member.

[0012] Preferably, the first predetermined shape comprises a central opening.

[0013] Preferably, the engagement member comprises one or more locking components configured to engage with the second predetermined shape of the locator.

[0014] Preferably, the one or more locking components extend radially from the engagement member.

[0015] Preferably, the locking component forces the engaging member into the locator.

[0016] Preferably, the locking component orients the first and second shapes to align the central opening with the working position.

[0017] Preferably, the second predetermined shape comprises a bowl portion and a lip for receiving the locking component.

[0018] Preferably, the one or more locking components have a predetermined length that fits between the bowl portion and the lip.

[0019] Preferably, the predetermined length of the one or more locking components prevents movement of the tool engagement coupler in the z-axis.

[0020] According to one aspect of the invention, there is provided a locator configured to guide a tool-engaging coupler to a work position, the tool-engaging coupler including an engagement member having a first predetermined shape and movable by a robotic arm, the locator including a tool opening configured to receive the engagement member and a second predetermined shape configured to engage with the first predetermined shape, the engagement of the first predetermined shape with the second predetermined shape reducing a level of spatial tolerance of movement of the robotic arm as the engagement member approaches the locator.

[0021] Preferably, the tool opening has a width determined by the positional accuracy of the robot arm.

[0022] Preferably, the second predetermined shape comprises a bowl portion.

[0023] Preferably, the second predetermined shape comprises a lip.

[0024] Preferably, the lip is configured to receive the at least one locking component from the engagement member when the at least one locking component moves to a predetermined radial extension.

[0025] According to one aspect of the present invention, there is provided a system configured to engage a tool-engaging coupler (102) with a locator positioned relative to a workpiece at a working position of the tool, the system comprising the tool-engaging coupler, the locator, and a robotic arm configured to control movement of the tool-engaging coupler.

[0026] Preferably, the system is configured to deploy a tool within a central opening of the tool-engaging coupler when the tool-engaging coupler and the locator are engaged.

[0027] Preferably, the robot arm has a spatial accuracy tolerance and the diameter of the tool opening of the locator is equal to or greater than the spatial accuracy tolerance of the robot arm.

[0028] According to one aspect of the present invention, there is provided a method for delivering a tool to a work location on a workpiece, the method comprising: moving a tool-engaging coupler toward a locator located at the work location to engage the locator; determining a distance of the tool-engaging coupler from the locator; moving the tool-engaging coupler into engagement with the locator; wherein the engagement is based on a first predetermined shape of an engaging member of the tool-engaging coupler and a second predetermined shape of the locator, and moving the tool-engaging coupler based on a level of spatial tolerance that decreases as the engaging member approaches the locator based at least in part on the first predetermined shape and the second predetermined shape.

[0029] Embodiments of the present invention will now be described, by way of example only, with reference to the figures, in which: [Brief explanation of the drawings]

[0030] [Figure 1] FIG. 1 illustrates a block diagram of a multi-function mobile platform in accordance with an aspect of the present invention. [Figure 2] 2 shows a simplified diagram of a tool engagement coupler, locator, and locator jig for use with the platform of FIG. 1; [Figure 3] 10 shows a simplified diagram illustrating movement of a tool engagement coupler. [Figure 4] 10A and 10B show schematic diagrams illustrating engagement of a tool engagement coupler with a locator. [Figure 5] 1 shows a simplified diagram of a locator jig with multiple locators. [Figure 6] 1 shows a schematic diagram of a locator. DETAILED DESCRIPTION OF THE INVENTION

[0031] System 100 includes a mobile platform (MP) 101, shown in Figure 1, and is a technology developed to perform various manufacturing tasks in a fully autonomous manner or in collaboration with a human operator. One use case of the present invention is the development of a tool engagement coupler (TEC) for use with drilling or other tools that have limited or unlimited access.

[0032] Air vehicle manufacturing traditionally requires skilled workers to work in unergonomic areas with limited access for extended periods of time to complete tasks. Traditional methods also have a wide range of process variables that are difficult to quantify, such as the accuracy of tool placement. This often results in defects and variability in the process completion time and cost of air vehicle manufacturing. Using autonomous devices such as system 100 to perform manufacturing tasks presents many challenges.

[0033] First, positioning a device to perform a task needs to be precise so that the action to be performed on the component (e.g., drilling) occurs at the required work position (WP). This is particularly important when manufacturing elaborate structures that require precision engineering, such as components for aerospace applications. The embodiments described herein achieve this precision by providing a tool-engagement coupler connected to a mobile platform (MP) and a locator positioned proximate to the work position that engage with each other to guide the tool to the work position.

[0034] Automated positioning of a device at a work position to perform a task is unlikely to be perfect every time. Therefore, it is desirable to position the device within a spatial tolerance (e.g., ±5 mm) when approaching the work position. The embodiments described below achieve this spatial tolerance by configuring the TEC and locator to guide the tool into the correct engagement position.

[0035] Next, Figure 1 will be described in detail.

[0036] System 100 includes MP 101, service unit 108, and control unit 110. MP 101 enables system 100 to automatically move to a work site location. MP 101 is connected to a robotic arm 104. Robotic arm 104 is connected to a tool unit (TU) 106, which is connected to a tool engagement coupler or coupling (TEC) 102. System 100 also includes a robot umbilical 112 connected from the system to the TEC, which includes components such as IO (input / output) supplies to operate the TEC.

[0037] The TEC 102 is connected to a robotic arm 104. The robotic arm 104 is responsible for positioning the TEC 102 in proximity to the locator and applying the force necessary for the TEC 102 to engage the locator. The robotic arm 104 houses components configured to operate mechanisms housed within the TEC 102 that enable the TEC to engage the locator. The components configured to operate the mechanisms housed within the TEC 102 are separate from the robotic arm 104. A robot umbilical 112, connected to the system 100 and the TEC 102, houses components configured to operate the TEC 102. The robotic arm 104 is connected to the system 100, which includes a service unit 108 and a control unit 110. The control unit 110 is pre-programmed to control the positioning and movement of the robotic arm.

[0038] A tool engagement coupler or coupling (TEC) 102 is configured to guide the tool to the WP. This is accomplished by guiding the TEC toward and engaging a locator positioned at a predetermined position relative to the workpiece. The guiding and engagement of the TEC 102 and the locator provides precise positioning of the tool on the workpiece when the TEC 102 and the locator engage. The guiding and engagement of the TEC 102 and the locator operate within a predetermined spatial tolerance (e.g., ±5 mm displacement of the tool from the WP) for initial positioning of the TEC 102 before final engagement with the locator.

[0039] As previously mentioned, the control unit 110 controls the motion and movement of the robot arm 104 to ensure that the tool engagement coupling is accurately positioned relative to the locator workpiece at the WP. As noted above, the locator is in a known, predetermined position with respect to the Cartesian axes and with respect to the rotational axes (roll, pitch, and yaw, referred to as A, B, and C). The positioning must not only be precise, but also smooth and consistent. If the movement is jerky and / or unclear, there may be problems with the coupling, or even worse, damage to the workpiece, engagement mechanism, and / or the tool being used.

[0040] The robotic arm 104 is connected to the system 100 and includes multiple joints along its length. The joints allow sections of the robotic arm 104 to rotate, pitch, and yaw relative to one another, thereby providing six degrees of freedom (6 DOF) of movement for the TEC 102. The multiple joints allow the robotic arm 104 to flexibly adopt different shapes, thereby enabling the shape of the robotic arm 104 to adapt to the WP's local environment. The joints include torque sensors that provide feedback to the control unit 110 of the forces applied to the robotic arm 104.

[0041] The TU 106 comprises tools and means for driving the tools. The TU 106 includes an advanced drilling unit (ADU). The TU 106 is connected to the robot arm via a tool changer configured to connect to different types of TUs. The TU 106 inserts tools into the TEC 102. The service unit 108 is configured to supply the components of the system 100 with substances necessary for their functioning, such as lubricants and compressed air.

[0042] The present invention seeks to address some of the problems associated with ensuring smooth delivery of a tool engagement coupling into engagement with a locator without the possibility of misalignment and collision.

[0043] The system 100 includes hardware and software capabilities for task automation. Through programming and processes, the MP can be moved to the location required for the task at hand. The MP contains motors (not shown) within its body that allow it to move around the factory floor or within a vehicle. The MP moves autonomously to the location of the workpiece where the tool is needed. Upon arriving at the location within the factory, the MP stops moving and the robotic arm 104 is deployed to move towards the locator.

[0044] 2 shows a two-dimensional representation of the tool engagement coupler 102. As previously mentioned, the TEC 102 is connected to the robot arm 104 via the TU 106. The TEC 102 comprises a first portion 202, a second portion (also referred to herein as a drive portion) 204, and an engagement member 206. A tool 208 provided by the TU 106 is housed by the engagement member 206. A locator 210 of a plurality of locators housed by a locator jig 212 is positioned below the engagement member 206. The locator jig 212 is attached to a workpiece 214.

[0045] The first portion 202 is positioned at the proximal end of the TEC 102 and forms a connection with the robot arm 104 via the TU 106. The first portion 202 comprises a motor configured to power components in the second portion 204. The motor may comprise a stepper motor that may be accompanied by an encoder that provides positioning feedback to a controller. The controller receives information from a proximity sensor located in the engagement member 206. The motor is controlled by the control unit 110. The motor is operated via controls that pass through the robot umbilical 112. The connection between the motor portion 202 and the drive portion 204 may comprise a drive shaft or a drive coupling.

[0046] The second portion 204 of the TEC 102 comprises components configured to drive an engagement mechanism in the engagement member 206. The engagement mechanism is detailed in FIG. 3. The drive portion 204 optionally comprises one or more of a series of gears (e.g., miter gears), a drive belt, and a drive belt tensioner connected to a drive shaft or drive coupling. In some embodiments, a worm drive is used to drive the engagement mechanism in the engagement member 206.

[0047] An engagement member 206 of the TEC 102 is configured to engage a locator on the WP. The engagement member 206 is also configured to accommodate a tool 208. The engagement member 206 has a predetermined shape adapted to engage a locator 210 having a second predetermined shape. The first and second predetermined shapes are described in more detail with reference to FIGS. 3, 4, and 6. Although not shown in FIG. 2, the engagement member 206 is optionally cylindrical in shape and includes an opening through its center through which the tool 208 can pass, as indicated by the arrow in FIG. 2. FIG. 3 displays a schematic two-dimensional side view of the engagement member 206 movable to engage the locator 210.

[0048] 3 shows a drive belt 302 connected to a worm drive 303. The worm drive 303 is coupled to a worm wheel 304 housed within an engagement member body 310. A rolling bearing is shown in contact with the worm wheel 304. A locking component 308 is shown connected to the engagement member body 310.

[0049] A drive belt 302 is shown connected to a worm drive 303 and adapted to rotate the worm drive (as indicated by the arrow above the component). The drive belt 302 and worm drive 303 are located within the second portion 204 in FIG. 2. The worm drive 303 contacts and drives the rotation of a worm wheel 304. A rotation bearing 306 is also incorporated to accommodate and facilitate the rotation of the worm wheel 304. The worm wheel 304 is connected to one or more locking components 308 via a rotating cam (not shown in FIG. 3) located within the engagement member body 310. As the worm wheel 304 rotates, the locking components 308 are extended radially from the engagement member body 310. While FIG. 3 shows the locking components 308 located outside the width of the engagement member body 310, the locking components 308 may alternatively be housed within the engagement member body 310.

[0050] Figure 3A shows arrows indicating the movement and rotation of drive belt 302, worm drive 303, worm wheel 304, and locking component 308. Figure 3B shows the final position of locking component 308 after rotation of drive belt 302, worm drive 303, and worm wheel 304. Engagement member 206 further includes a central opening 312 configured to receive a tool or tool mount. Central opening 312 is optionally configured to hold the tool in place.

[0051] In the extended position, the locking component 308 interlocks with the locator, and the central opening lies within a known spatial tolerance with the WP. While the locking component 308 is spherically shaped in the example shown in FIG. 3, this is not limiting and other suitable shapes and sizes may be used. The spherical shape of the locking component 308 allows for smoother insertion of the locking component 308 into a corresponding slot in the locator.

[0052] The engagement member body 310 also optionally includes tubing directed toward the end of the engagement member 206. The tubing is connected to a vacuum housed in either the TEC 102 or the MP 101, and thus the tubing optionally extends through the robot arm. The vacuum operates through the tubing to remove chips at the workpiece.

[0053] FIG. 4 shows a schematic two-dimensional side view of the engagement member 206 engaged with the locator 210. The locator 210 is fixed to a locator jig 212. The locator 210 is optionally a bushing. The locator 210 is fixed to the locator jig 212 by any suitable method, including mechanical fastening, adhesive fastening, magnetic fastening, etc. The locator 210 includes a tool opening 410 and an opposing work site opening 412 closest to the work site. Although not shown in FIG. 4 , the tool opening 410 may be circular. To ensure that the locator 210 can position the TEC 102 precisely enough to receive the engagement member 206, the diameter of the tool opening 410 may be determined by the spatial precision of the robot arm 104. For example, the diameter may be equal to or greater than the spatial precision of the robot arm. The locator 210 further comprises a lip (also referred to herein as a lipped portion) 416 that extends into the tool opening 410 on the tool opening 410 side of the locator 210 .

[0054] The engagement member 206 and the locator 210 cooperate to allow the robot arm 104 to position the TEC 102 at the WP within a predetermined spatial tolerance. FIG. 4 shows the engagement member body 310 having a first predetermined shape with a tapered end 314 that forms a conical shape in three dimensions. The locator 210 is shown having a second predetermined shape with a sloped, “bowl-like” interior structure. As a result, when the tapered end 314 of the engagement member 206 contacts the sloped interior structure of the locator 210 and is moved toward the locator 210, the central opening 312 is moved to the center of the locator 210 at the WP. Thus, the level of movement or spatial tolerance of the TEC 102 by the robot arm 104 decreases as the engagement member 206 approaches the locator 210 based at least in part on the first predetermined shape of the engagement member body 310 and the second predetermined shape of the locator 210. When the engagement member 206 is positioned above the locator, the movement or spatial tolerance of the TEC 102 is determined by the range of motion of the robot arm 104. In contrast, when the engagement member is positioned with the locator, the movement or spatial tolerance of the TEC 102 is greater toward the top of the locator 210 compared to the bottom.

[0055] The robot arm, and therefore the TEC 102, is more compliant in the x- and y-axes, as appropriate, depending on the control mode, compared to the z-axis (shown in FIG. 4). The increased compliance also extends to the pitch, roll, and yaw of the robot arm in some cases. The TEC 102 can now be moved in the z-axis by the robot arm 104. As a result, the position and configuration of the robot arm 104 (and therefore the position of the TEC 102) responds to the alignment of the engagement member 206 and the locator 210 while the TEC is being moved in the z-direction. Once the TEC 102 is correctly positioned, the robot arm 104 moves the TEC 102 a predetermined amount in the z-axis, thereby engaging the TEC 102 and the locator 210 at the final WP.

[0056] When aligned, the engagement member 206 is moved toward the workpiece by the robot arm 104 and the tapered end 314 of the engagement member 206 contacts the edge of the opening of the locator 210, thereby guiding the engagement member 206 toward the center of the locator 210.

[0057] The engaging member 206 and the locator 210 also cooperate to lock the position of the central opening 312 at the WP. The locator 210 includes a lipped portion 416 around the edge of the tool opening that is configured to receive the locking component 308 of the engaging member 206. As a result, the engaging member 206 is prevented from moving within the locator 210 in any direction other than the z-axis. Furthermore, the locking component 308 also prevents the engaging member 206 from moving in the x- and y-axes of the locator 210. The locking component 308 exerts a force against the inside of the locator 210, thereby holding the engaging member 206 in place. Thus, the engaging member 206 is held in a stiff position when the tool 208 is delivered to the WP through the central opening 312.

[0058] The movements that are restricted in different modes of operation need not be as described above: different axes can be simply rigid or compliant, depending on the use case, as described in more detail below.

[0059] The extension length 418 of the locking component 308 is preconfigured to a length based on the width 420 of the lipped portion of the locator 210. Thus, the extension of the locking component 308 contributes to the accuracy of delivery of the tool 208 to the WP by ensuring the locking component 308 is a predetermined distance from the lip 416 of the locator 210. The locking component 308 also ensures a predetermined vertical displacement from the work location by extending the locking component 308 into the angled interior structure of the locator 210 to move the engaging member 206 away from the WP in the z-direction.

[0060] The engagement of the first predetermined shape of the engagement member 206 with the second predetermined shape of the locator 210 means that precise positioning of the engagement member 206 is not entirely dependent on the control of the control unit 110 of the robot arm 104. The control unit 110 is responsible for positioning the TEC 102 within the spatial tolerance of the WP (e.g., ±20 mm), but fine positioning is achieved using the features described with respect to the engagement member 206 and the locator 210.

[0061] Reducing the fine positioning burden on the control unit 110 increases the speed and efficiency of delivering tooling to a work site. Furthermore, it means that less precise robotic systems, such as cobots, can be used for precision tooling with the assistance of the TEC 102 and locator 210. Considering that the robot arm 104 can be used to move the TEC 102 in space-constrained environments, the control unit may have to process numerous parameters related to the configuration of the robot arm 104 when making fine adjustments to the position of the TEC 102 (e.g., the six degrees of freedom of movement of the joints of the robot arm 104). Because the fine positioning is achieved automatically due to the first and second predetermined shapes of the engagement member 206 and locator 210, respectively, as described above, the processing workload is reduced by positioning the engagement member 206 and locator 210 at the WP.

[0062] Due to the configuration of the TEC 102, it can be powered using electricity alone. While typical clamping systems require a compressed air supply to clamp the tool mechanism to the work site, this is not a necessary requirement for the features shown in Figures 1-4. Because no compressed air supply is required and the weight of an electric system is reduced compared to pneumatic or hydraulic systems, the system 100 can be integrated into a mobile platform. Thus, the system can be programmed to automatically move to the work site and can also be moved to restricted spaces or hazardous environments.

[0063] The contribution of the features displayed in FIGS. 1-4 can be explained by describing a step-by-step process for delivering a tool to a work site. First, the control unit 110 moves the robot arm 104 to the work area using the arm's six degrees of freedom to avoid restricted access to the work site (FIG. 1). The control unit moves the robot arm 104 and TEC 102 toward the work site where a locator jig 212 with locator(s) 210 is positioned. The control unit then commands the robot arm 104 to apply a force toward the locators, thereby moving the robot arm in the z-direction as the engagement member 206 approaches the locators 210, and commands the robot arm 104 to be compliant in one or more axes and immobile in at least one axis, depending on the relative orientation of the TEC 102 and the locators 210. When the tapered end of the engagement member 206 contacts the angled internal structure of the locator 210, the engagement member 206 slides toward the center of the locator 210. After the tapered end of the engagement member 206 engages with the angled internal structure of the locator 210, movement of the TEC 102 becomes more constrained in one or more axes (e.g., the x-axis and y-axis).

[0064] When the engagement member 206 engages the locator 210, the control unit 110 activates a motor in the first portion 202 of the TEC 102, which drives components in the second portion 204 of the TEC 102. Activation of the motor is initiated in response to a torque sensor in the robot arm 104 detecting a change in force applied to the robot arm 104 in response to the engagement member 206 contacting the locator 210. Activation is potentially facilitated by a proximity sensor on or within the engagement member 206. This activates a mechanism within the engagement member 206, causing a locking component 308 to extend radially from the engagement member 206. The locking component 308 extends below a lip 416 on the top edge of the locator 210 and applies a force to the inner wall of the locator 210, thus locking the engagement member 206 in place and preventing movement of the TEC in the x-, y-, z-, pitch, roll, and yaw axes. In the locked position, the central opening 312 of the engagement member 206 is in the working position. Sensors positioned on or within the engagement member 206 optionally track the extension of the locking components 308 to detect when they are positioned under the lip 416. Similar sensors may also detect the rotation of a cam to indirectly detect the extension of the locking components 308. During extension of the locking components 308, the control unit 110 commands the robot arm 104 to operate in one of the control modes (e.g., Cartesian impedance control mode). As a result, the locking components 308 apply forces to the internal structure of the locator 210, and the engagement member 206 is moved to a precise, predetermined position in the x-, y-, and z-axes, as well as configured pitch, yaw, and roll orientations.

[0065] The above examples illustrate how the features included in the embodiment of Figures 1-4 interact with each other to position a tool at a predetermined work location.

[0066] FIG. 5 shows a schematic diagram of multiple locators 210 secured within a locator jig 212. Before a work task is performed, the locator jig 212 is secured to an area where one or more work locations are to be located on a workpiece 214. While FIG. 5 depicts the locator jig 212 arranging the locators 210 in a row, the locators may be arranged in any suitable configuration (e.g., a matrix of locators 210, etc.). The locators 210 are positioned above predetermined WPs by the locator jig 212. Thus, the locators 210 are positioned to guide the engagement members 206 to the correct positions for sequential delivery of tools 208 to the multiple WPs defined by the locators 210.

[0067] 6A-6D show schematic diagrams of the locator. FIG. 6A shows a two-dimensional side view of locator 210 with the internal structure visible. FIG. 6B shows a top view of locator 210. FIG. 6C shows an opaque two-dimensional side view of locator 210. FIG. 6D shows a diagram of locator 210.

[0068] Two locking components 308 (shown in FIGS. 3 and 4 ) are included to illustrate how the locking components 308 interact with the internal structure of the locator 210. The internal structure of the locator 210 includes a lip 416, a sloped bowl portion 602, a tool opening 410, a work site opening 412, and an outer lip 604. The lip 416 extends around the entire periphery of the locator 210. The internal structure of the locator 210 further includes a sloped bowl portion 602 that surrounds the central work site opening 412 of the locator 210. The center of the work site opening 412 is located at the WP. The locator may also include a threaded portion 606 on its underside that can be secured to the locator jig 212. Although not illustrated in FIG. 6 , the locator 210 may use any suitable securing mechanism. The locator also includes an outer lip 604 at its periphery 608 such that the locator 210 extends a predetermined distance from the top side of the locator jig 212. The total circumference of the tool opening 410 is based on the limit of how close the robot arm 104 can position the engagement member to the WP before requiring assistance from the guidance provided by the locator 210.

Claims

1. a tool-engaging coupler configured to deliver a tool to a work location on a workpiece, the tool-engaging coupler further being movable by a robot arm to engage a locator at the work location; the tool engagement coupler includes an engagement member having a first predetermined shape adapted to engage with the locator having a second predetermined shape; The tool engagement coupler is adapted to be moved by the robot arm based on a level of spatial tolerance that decreases as the engagement member approaches the locator based at least in part on the first predetermined shape and the second predetermined shape.

2. The tool-engaging coupler of claim 1 , wherein the tool-engaging coupler is compliant in multiple axes during movement of the tool-engaging coupler toward the working position.

3. 3. The tool engaging coupler of claim 1 or 2, wherein the movement of the tool engaging coupler is configured to be constrained from movement in one or more axes.

4. A tool engaging coupler according to any preceding claim, wherein the tool engaging coupler is movable in the z-axis by the robot arm when the engaging member approaches the locator.

5. 5. A tool engagement coupler according to any one of claims 1 to 4, wherein when the first predetermined feature and the second predetermined feature are engaged, the movement of the tool engagement coupler is constrained in one or more axes.

6. 6. The tool engaging coupler of claim 1, wherein the tool engaging coupler is configured to be compliant in at least one of an x-axis, a y-axis, a z-axis, a pitch axis, a roll axis, and a yaw axis.

7. 7. A tool engagement coupler according to any one of claims 1 to 6, wherein the first predetermined shape and the second predetermined shape are configured to move the tool engagement coupler to move the engagement member towards the working position.

8. A tool engagement coupler according to any preceding claim, wherein the first predetermined shape comprises a tapered shape at a distal end of the engagement member.

9. A tool engaging coupler according to any preceding claim, wherein the first predetermined shape comprises a central opening.

10. A tool engagement coupler according to any preceding claim, wherein the engagement member comprises one or more locking components configured to engage the second predetermined shape of the locator.

11. The tool engagement coupler of claim 10 , wherein the one or more locking components extend radially from the engagement member.

12. 12. A tool engagement coupler according to claim 10 or 11, wherein the locking component forces the engagement member into the locator.

13. A tool engagement coupler according to any one of claims 10 to 12, wherein the locking component orients the first shape and the second shape to align the central opening with the working position.

14. A tool engaging coupler according to any one of claims 10 to 13, wherein the second predetermined shape comprises a bowl portion and a lip for receiving the locking component.

15. The tool engaging coupler of claim 14 , wherein the one or more locking components have a predetermined length that fits between the bowl portion and the lip.

16. The tool-engaging coupler of claim 15 , wherein the predetermined length of the one or more locking components prevents movement of the tool-engaging coupler in the z-axis.

17. a locator configured to guide a tool-engaging coupler to a work position, the tool-engaging coupler including an engagement member having a first predetermined shape and movable by a robotic arm, the locator comprising: a tool opening configured to receive the engagement member; a second predetermined shape configured to engage with the first predetermined shape; Equipped with A locator, wherein the engagement of the first predetermined shape with the second predetermined shape reduces the level of spatial tolerance of movement of the robot arm as the engaging member approaches the locator.

18. The locator of claim 17 , wherein the tool opening has a diameter determined by the spatial accuracy of the robot arm.

19. 19. The locator of claim 17 or 18, wherein the second predetermined shape comprises a bowl portion.

20. The locator of any one of claims 17 to 19, wherein the second predetermined shape comprises a lip.

21. 21. The locator of claim 20, wherein the lip is configured to receive the at least one locking component from the engaging member when the at least one locking component moves to a predetermined radial extension.

22. 1. A system configured to engage a tool engagement coupler with a locator positioned relative to a workpiece at a working position of the tool, the system comprising: A tool engaging coupler according to any one of claims 1 to 16; A locator according to any one of claims 17 to 21; a robotic arm configured to control movement of the tool engagement coupler; A system comprising:

23. 23. The system of claim 22, wherein the system is configured to deploy the tool within a central opening of the tool-engaging coupler when the tool-engaging coupler and the locator are engaged.

24. 24. The system of claim 22 or 23, wherein the robot arm has a spatial accuracy tolerance, and the diameter of the tool opening of the locator is equal to or greater than the spatial accuracy of the robot arm.

25. 1. A method for delivering a tool to a work location on a workpiece, comprising: moving a tool engagement coupler toward the locator so as to engage the locator in the working position; determining a distance of the tool engaging coupler from the locator; moving the tool-engaging coupler into engagement with the locator, wherein the engagement is based on a first predetermined shape of an engagement member of the tool-engaging coupler and a second predetermined shape of the locator; moving the tool engagement coupler based on a level of spatial tolerance that decreases as the engagement member approaches the locator based at least in part on the first predetermined shape and the second predetermined shape; A method comprising:

Images