Correspondence device and correlation method

Abstract

To enable a workpiece to be quickly and accurately placed without the need for an expensive and time-consuming set-up process or locating process.SOLUTION: An indexing apparatus 100 comprises: a fixture tool 102 configured to support a workpiece and movable relative to an operation cell 106; an indexing feature 104 fixed relative to the fixture tool; a gripper 108 configured to engage the indexing feature; and a controller 110 in electrical and / or data communication with the gripper. The controller is configured to determine a location of the gripper engaged with the indexing feature and to locate the fixture tool relative to the operation cell 106 from the determined gripper location of the gripper.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates generally to manufacturing, and more particularly to a registration apparatus and method for registration during the manufacturing process. [Background technology]

[0002] Many structures, parts, and components are manufactured using large, automated machines that have a fixed base and operate under computer control along predetermined tool paths. Such manufacturing techniques require precise registration of the workpiece relative to the machine. One method for registering the workpiece is to probe the workpiece at various locations and, based on the probed locations, align, or "zero," the machine's work tool to the workpiece's nearest location. Another method for registering the workpiece is to use a fixture to secure the workpiece in a specific, repeatable position. However, both methods can be time-consuming and expensive processes that require extensive setup each time the workpiece is moved to a new work location or a new workpiece is moved to the work location. For large structures, such as aircraft spars, airfoils, and fuselage sections, this problem is amplified, potentially requiring numerous probe locations or very large fixtures. Furthermore, neither of these methods is conducive to continuous manufacturing, where workpieces must be moved quickly and accurately from one work location to another. Accordingly, those skilled in the art continue to conduct research and development in the area of ​​manufacturing registration and would therefore find useful apparatus and methods to address the above-mentioned concerns.

[0003] The Abstract of EP3733387 states, "There is provided a reinforced composite material placement system (1100), comprising: a longitudinal end effector (1104) having a first attachment point and a second attachment point; a first rotating arm (1108) having a first connector configured to interface with the first attachment point; a first movement system configured to move the first rotating arm in a manufacturing environment; a second rotating arm (1110) having a second connector configured to interface with the second attachment point; and a second movement system configured to move the second rotating arm in the manufacturing environment."

[0004] The abstract of EP 2923794 states, "A system for assembly manufacturing may include at least one tucking cell (20) configured to perform at least one tack fastening operation on a workpiece, at least one fastening cell (22) configured to perform at least one final fastening operation on the workpiece, and a material handling system (26) connecting the tucking cell (20) and the fastening cell (22), wherein the material handling system (26) positions the workpiece inside the tucking cell (20) and the material handling system transfers the workpiece from the tucking cell (20) to the fastening cell (22)."

[0005] The Abstract of EP 318699 states, "A system (100) and method (1100) are provided for proximity detection in a fabrication environment. One embodiment is a method (1100) for reporting a proximity condition in an assembly environment (130). The method (1100) includes inserting (1102) an arm (1026) of a bracket (1020) into an interior (1004) of a part (1000) held by a cradle (1010) and worked on by a robot (140, 1030, 1250); positioning (1104) an engagement feature (1016) of the bracket (1020) in contact with an engagement feature (1023) of the cradle (1010); and positioning (1104) the bracket (1020) in contact with an engagement feature (1023) of the cradle (1010). and operating (1106) sensors (120, 1028, 1270) of the robot (140, 1030, 1250) to directly detect (1106) the location of a first proximity detector (160, 300, 410, 1260) worn by the technician (150, 920) and the location of a second proximity detector (162, 300, 420, 430, 1290) of the robot (140, 1030, 1250), and instructing (1108) the first proximity detector (160, 300, 410, 1260) to provide an alert to the technician (150, 920) if the distance between the first proximity detector (160, 300, 410, 1260) and the second proximity detector (162, 300, 420, 430, 1290) is less than a threshold value.

[0006] The abstract of EP 0807504 states, "A method for producing a laid-up, bonded, and cured composite part includes filling grooves (64) on the facing surface of a tool (32) with a foamable, self-skinning, sacrificial material and covering the facing surface of the tool with a caul sheet. The tool is heated to cure the foam, filling the grooves and forming a hard, smooth skin layer over the foam flush with the facing surface of the tool. A series of plies (85) are laid up on the facing surface of the tool to form the tool-side skin, and other components of the part (84) are laid up over the tool-side skin plies. An adhesive / resin matrix is ​​coated or pre-impregnated onto these skin plies and the adhesive / curing components to form a rigid, integral assembly of the skin and component." "The assembly is then created. A vacuum bag (71) is applied over the laid-up skins and components. An adhesive / resin matrix is ​​allowed to bond / cure, transforming the skins and components into a rigid, one-piece assembly. The tool is fixed in a known position on the CNC machine bed, and the tool's facing surface is positioned in a known location for edge routing of the rigid, one-piece assembly by the machine tool. The machine tool's cutter (68) is guided on a predetermined path around the tool's facing surface, and the cutter extends into a groove below the tool's facing surface to cut a peripheral edge surrounding the rigid, one-piece assembly. Once edge routing is complete, the rigid, one-piece assembly is the finished part and is removed from the tool's facing surface." Summary of the Invention

[0007] The following is a non-exhaustive list of examples of subject matter according to the present disclosure, which may or may not be claimed.

[0008] In one example, a disclosed alignment apparatus includes a fixture movable relative to a work cell and a registration mechanism fixed relative to the fixture. The alignment apparatus also includes a gripper configured to engage the registration mechanism. The alignment apparatus further includes a controller in communication with the gripper. The controller is configured to position the fixture relative to the work cell from a gripper position of the gripper engaged with the registration mechanism.

[0009] In one example, a disclosed manufacturing system includes an automated machine located within a work cell and configured to perform at least one manufacturing process. The manufacturing system also includes a fixture configured to support a workpiece and movable relative to the work cell, and a registration mechanism fixed relative to the fixture. The manufacturing system further includes a gripper configured to engage the registration mechanism. The manufacturing system also includes a controller in communication with the gripper and the automated machine. The controller is configured to position the fixture relative to the work cell from a gripper position of the gripper engaged with the registration mechanism. The controller is also configured to register the automated machine with the fixture position of the fixture.

[0010] In one example, the disclosed manufacturing method includes the steps of: (1) moving a fixture relative to a work cell; (2) engaging an association mechanism with a gripper; (3) positioning the fixture relative to the work cell from a gripper position of the gripper engaged with the association mechanism; and (4) associating an automated machine with the fixture position of the fixture.

[0011] Other examples of the disclosed apparatus, systems, and methods will become apparent from the following detailed description, the accompanying drawings, and the accompanying clauses. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a schematic block diagram of an example of an association device. [Figure 2] FIG. 1 is a schematic perspective view of an example of a manufacturing system using an association device. [Figure 3] 1 is a schematic perspective view of an example of an interface device, an association mechanism, and a mounting fixture of an association apparatus. [Figure 4] FIG. 1 is a schematic plan view of an example of an association device. [Figure 5] FIG. 1 is a schematic plan view of an example of an association device. [Figure 6] FIG. 1 is a schematic plan view of an example of an association device. [Figure 7] FIG. 10 is a schematic block diagram of an example of a process used to determine the location of a fixture in an alignment device. [Figure 8A] 1 is a schematic perspective view of an example of a gripper of an interface device of an association apparatus; [Figure 8B] FIG. 2 is a schematic perspective view of an example of an association mechanism of the association device. [Figure 9A] 1 is a schematic perspective view of an example of a gripper of an interface device of an association apparatus; [Figure 9B] FIG. 2 is a schematic perspective view of an example of an association mechanism of the association device. [Figure 10] 1 is a schematic perspective view of an example of a manufacturing system. [Figure 11] 1 is a schematic perspective view of an example of a manufacturing system using an association device; [Figure 12] FIG. 1 is a schematic plan view of an example of an association device. [Figure 13] 1 is a schematic perspective view of an example of an interface device, an association mechanism, and a mounting fixture of an association apparatus. [Figure 14] FIG. 1 is a schematic plan view of an example of an association device. [Figure 15] FIG. 1 is a schematic plan view of an example of an association device. [Figure 16] FIG. 10 is a schematic block diagram of an example of a process used to determine the location of a fixture in an alignment device. [Figure 17] 1 is a schematic perspective view of an example of an association mechanism and attachment of an association device. FIG. [Figure 18] 1 is a schematic perspective view of an example of an association mechanism and attachment of an association device. FIG. [Figure 19] 1 is a schematic perspective view of an example of an association mechanism and attachment of an association device. FIG. [Figure 20] 1 is a schematic perspective view of an example of a manufacturing system. [Figure 21] 1 is a schematic perspective view of an example of a manufacturing system using an association device; [Figure 22]FIG. 1 is a schematic plan view of an example of an association device. [Figure 23] 1 is a schematic perspective view of an example of an interface device, an association mechanism, and a mounting fixture of an association apparatus. [Figure 24] FIG. 10 is a schematic block diagram of an example of a process used to determine the location of a fixture in an alignment device. [Figure 25] 1 is a schematic elevational view of an example of an alignment mechanism and fixture of an alignment device. FIG. [Figure 26] 1 is a schematic elevational view of an example of an alignment mechanism and fixture of an alignment device. FIG. [Figure 27] 1 is a schematic elevational view, partially in section, showing an example of a probe, a registration mechanism, and a fixture of an interface device of a registration apparatus. FIG. [Figure 28] 1 is a schematic perspective view of an example of a manufacturing system. [Figure 29] FIG. 1 is a flow diagram of an example of a manufacturing method. [Figure 30] FIG. 1 is a flow diagram of an example of a manufacturing method. [Figure 31] FIG. 1 is a flow diagram of an example of a manufacturing method. [Figure 32] FIG. 2 is a schematic block diagram of an example of a controller of the association device. [Figure 33] FIG. 1 is a flow diagram of an aircraft production and service method. [Figure 34] FIG. 1 is a block diagram of an aircraft. DETAILED DESCRIPTION OF THE INVENTION

[0013] The following detailed description refers to the accompanying drawings, which illustrate examples described by the present disclosure. Other examples having different structures and processes do not depart from the scope of the present disclosure. Similar reference numbers may refer to the same features, elements, or components in different drawings.

[0014] Illustrative, non-exhaustive examples of the subject matter according to the present disclosure are provided below. These may or may not be claimed. Reference herein to an "example" means that one or more features, structures, elements, components, characteristics, and / or operational steps described in connection with the example are included in at least one embodiment and / or implementation of the subject matter according to the present disclosure. Thus, throughout this disclosure, the phrases "an example," "another example," "an example," and similar language can, but do not necessarily, refer to the same example. Furthermore, inventive subject matter characterizing any example may or may not include inventive subject matter characterizing any other example. Furthermore, inventive subject matter characterizing any example may or may not be combined with inventive subject matter characterizing any other example.

[0015] By way of example, and generally referring to Figures 1-33, the present disclosure describes a registration apparatus 100 used to position and register a workpiece 170 during a manufacturing process, a manufacturing system 168 utilizing the registration apparatus 100, and manufacturing methods 1000, 2000, 3000 for positioning and registering a workpiece 170 using the registration apparatus 100.

[0016] FIG. 1 schematically illustrates an example of a registration apparatus 100. Generally, the registration apparatus 100 provides a means for accurately and repeatably determining the position of a workpiece 170 relative to a frame of reference 216 defined by a fixed coordinate system 112. FIG. 1 also schematically illustrates an example of a manufacturing system 168 that includes the registration apparatus 100. The manufacturing system 168 includes, or forms at least a portion of, a work cell 106. An automated machine 128 is disposed within the work cell 106 and is configured to perform at least one manufacturing process on the workpiece 170. The work cell 106 is defined or described by the fixed coordinate system 112 and includes a work envelope 140. The work envelope 140 defines a three-dimensional volume within the work cell 106 that is described by the fixed coordinate system 112 within which the automated machine 128 operates.

[0017] 1 , the alignment apparatus 100 includes a fixture 102. The fixture 102 is configured to securely hold a workpiece 170. The fixture 102 includes various suitable holding mechanisms 260 that allow the workpiece 170 to be secured or otherwise held in the fixture 102. The fixture 102 is movable relative to the work cell 106, for example, relative to an automated machine 128 located within the work cell 106. For example, the fixture 102, with the workpiece 170 secured to the fixture 102, is moved to a work location 258 within the work envelope 140 of the work cell 106.

[0018] As used herein, the term "work position 258" generally refers to the spatial situation of the fixture 102, and therefore the workpiece 170, when the fixture 102 is moved within the work cell 106 for the performance of at least one manufacturing operation on the workpiece 170 by the automated machine 128. This disclosure recognizes and takes into account that the work position 258 may not be precisely known when the fixture 102 is moved within the work cell 106. Accordingly, the correlation apparatus 100 is configured to determine the position of the fixture 102 (also referred to herein as the fixture position 118) and therefore the position of the workpiece 170 (also referred to herein as the workpiece position 262) relative to the frame of reference 216 when the fixture 102 is in the work position 258.

[0019] The alignment device 100 includes an alignment mechanism 104. The alignment mechanism 104 is fixed relative to the fixture 102. In other words, the position of the alignment mechanism 104 relative to the fixture 102 remains constant regardless of the position (or change in position) of the fixture 102 relative to the frame of reference 216. In one example, the alignment mechanism 104 is coupled to the fixture 102. In another example, the alignment mechanism 104 is disposed on the fixture 102. In yet another example, the alignment mechanism 104 forms part of (e.g., is integral with) the fixture 102.

[0020] Throughout this disclosure, the term "position" refers to the linear situation of an object along one or more orthogonal axes in three-dimensional space, e.g., along fixed coordinate system 112. In addition, in some examples, the term "position" also refers to the angular situation (e.g., orientation) of an object about one or more orthogonal axes in three-dimensional space, e.g., about fixed coordinate system 112. In general, the "position" of an object refers to the X-position of at least a portion of one or more exterior surfaces of the object (e.g., the X-coordinates of a plurality of points representing at least a portion of the exterior surfaces), the Y-position of at least a portion of one or more exterior surfaces of the object (e.g., the Y-coordinates of a plurality of points representing at least a portion of the exterior surfaces), and the Z-position of at least a portion of one or more exterior surfaces of the object (e.g., the Z-coordinates of a plurality of points representing at least a portion of the exterior surfaces).

[0021] 1 , the registration apparatus 100 includes an interface device 220. The interface device 220 is configured to interface with the registration mechanism 104 and to position the registration mechanism 104 relative to a frame of reference 216, such as within the workcell 106. The interface device 220 is configured to generate interface data 222 representing the position of the registration mechanism 104 relative to the frame of reference 216 (also referred to herein as the registration mechanism position 116). As will be described in more detail later in this specification, the interface device 220 may interface with and position the registration mechanism 104 using at least one of the gripper 108, the sensor 184, and the plurality of probes 202.

[0022] The registration apparatus 100 also includes a controller 110. The controller 110 is in communication (e.g., electrical and / or data communication) with an interface device 220. The controller 110 is configured to process interface data 222 generated by the interface device 220 and to determine a registered mechanism position 116 based on the interface data 222. The controller 110 is also configured to determine a current (e.g., real-time, actual) position of the fixture 102, and therefore of the workpiece 170, relative to the frame of reference 216 based on the registered mechanism position 116. The automated machine 128 is registered with respect to the fixture 102 based on this determined position (fixture position 118) of the fixture 102.

[0023] In the disclosed example, the geometry of the workpiece 170, the geometry of the fixture 102, and the geometry of the engagement mechanism 104 are known. As used herein, the "geometry" of an object refers to the size, shape, and form of the object, as well as the surface contours of the object. The geometry of an object may include the internal geometry of the object and / or the external geometry of the object. For example, the geometry of the workpiece 170 refers to the size, shape, and form of the workpiece 170, as well as the surface contours of the workpiece 170.

[0024] Additionally, workpiece 170 is mounted or otherwise fixed to fixture 102 at a known position relative to fixture 102. In other words, the position of workpiece 170 relative to fixture 102 (workpiece position 262) is known and remains constant regardless of the position (or change in position) of fixture 102 relative to frame of reference 216, such as when fixture 102 moves in and out of work cell 106. Similarly, the position of workpiece 170 is fixed and remains constant relative to reference mechanism 104.

[0025] Therefore, the associated mechanism position 116 can be used to determine the fixture position 118. The fixture position 118 can then be used to assume the workpiece position 2622 to be within tolerance. In other words, the fixture position 118 represents the immediate position of the fixture 102 and workpiece 170 relative to the frame of reference 216. Therefore, throughout this disclosure, unless otherwise specified, the term "fixture position 118" represents and incorporates the position of the workpiece 170 (workpiece position 262).

[0026] In one example, the controller 110 is configured to identify the fixture 102, registration mechanism 104, and workpiece 170 on which the manufacturing process will be performed prior to the initiation of the positioning and registration process. In one example, the fixture type, registration mechanism type, and / or workpiece type can be loaded into the program prior to execution of the positioning and registration instructions. In another example, the program can actively identify and select the fixture type, registration mechanism type, and / or workpiece type from an optional database based on one or more predetermined selection criteria.

[0027] Thus, the geometry of fixture 102, the geometry of reference feature 104, and the geometry of workpiece 170 are known based on the fixture type, the reference feature type, and / or the workpiece type identified by controller 110. For example, the program loads digital model 120 representing fixture 102, reference feature 104, and workpiece 170. The geometry of fixture 102 (also referred to herein as fixture geometry 264), the geometry of reference feature 104 (also referred to herein as reference feature geometry 266), and the geometry of workpiece 170 (also referred to herein as workpiece geometry 268) are represented by or extracted from digital model 120 ( FIG. 1 ).

[0028] In one example, digital model 120 includes a digital representation of fixture 102, reference feature 104, and workpiece 170. In another example, digital model 120 includes a digital representation of fixture 102 in combination with reference feature 104 secured to fixture 102 and workpiece 170. Thus, digital model 120 represents the position of reference feature 104 and / or workpiece 170 relative to fixture 102.

[0029] 1 , the controller 110 is configured to match the reference feature geometry 266 to the reference feature location 116 represented by the interface data 222 during the registration and registration process. For example, the controller 110 registers a geometric representation of the reference feature 104 of the digital model 120 to the reference feature location 116. The controller 110 then determines a position of the digital model 120 relative to the frame of reference 216 (referred to herein as the model location 126), thereby positioning the digital model 120 within the frame of reference 216. Registration of the digital model 120 to the reference feature location 116 may be performed using any one of a variety of data computing techniques, such as transformation of point cloud data, that best aligns a set of data points (e.g., representing the digital model 120) with a set of reference data points (e.g., representing the reference feature location 116). The controller 110 then determines the position of the fixture 102 and the position of the workpiece 170 (fixture position 118) relative to the reference frame 216 based on the model position 126. For example, the fixture position 118 is assumed to be the model position 126 within tolerance.

[0030] The automated machine 128 is then mapped to the fixture 102 based on the fixture position 118 relative to the frame of reference 216. The automated machine 128 operates along a well-defined, programmed (e.g., numerically controlled) motion cycle or toolpath relative to the frame of reference 216 in at least one dimension of the fixed coordinate system 112.

[0031] In one example, automated machine 128 includes a robotic arm 226 having multiple degrees of freedom and an end effector 228 coupled to a working end of robotic arm 226. End effector 228 includes or takes the form of at least one work tool configured to perform at least one manufacturing operation on workpiece 170. Robotic arm 226 is configured to move end effector 228 relative to fixture 102 and workpiece 170 along a predetermined tool path under computer control based on fixture position 118.

[0032] In general, the positioning and alignment processes described herein can be performed in combination with, or as a first step in connection with, any one of a variety of additive or subtractive machining processes. Accordingly, the automated machine 128 can perform any one of a variety of manufacturing processes on the workpiece 170, including, but not limited to, drilling, milling, fastening, pre-cured and / or post-cured composite assembly processes (e.g., material layup, lamination, etc.). Generally, the end effector 228 includes appropriate tooling configured to perform the associated manufacturing process.

[0033] Because the geometry of workpiece 170 is known, and because the position of workpiece 170 is assumed to be known or within tolerance relative to fixture 102, mapping automated machine 128 to fixture 102 based on fixture position 118 results in mapping automated machine 128 to workpiece 170. Once automated machine 128 is mapped to fixture position 118, automated machine 128 operates along a programmed toolpath to perform at least one manufacturing operation on workpiece 170 in a known manner. The geometry of workpiece 170 and the known position of workpiece 170 relative to fixture 102 are incorporated into and accounted for by the programmed toolpath of automated machine 128.

[0034] This disclosure recognizes and takes into account that the geometry of workpiece 170 may change as a result of manufacturing (e.g., assembly or machining) processes performed on workpiece 170. However, the position of workpiece 170 relative to fixture 102 and mating mechanism 104 does not change due to operations other than the manufacturing process. Therefore, any distortion, movement, etc. of workpiece 170 is within tolerance during the manufacturing process and does not affect the position of workpiece 170 out of tolerance. In other words, at each stop along the complete manufacturing process, the only change in workpiece 170 is the change in geometry due to the various manufacturing processes.

[0035] Changes in the geometry of the workpiece 170 resulting from any manufacturing process are also known or assumed to be within tolerance based on theoretical additions or subtractions from previous manufacturing processes. For example, the workpiece geometry 268 (e.g., as represented by the digital model 120) is updated based on additive or subtractive manufacturing processes performed on the workpiece 170.

[0036] When the fixture 102 and workpiece 170 are moved by a second automated machine 174 (FIGS. 10, 20, and 28) to a subsequent work location 258, such as a second work cell 172, for performance of a subsequent manufacturing operation on the workpiece 170, the registration mechanism 104 is deployed, the fixture location 118 is determined, and the second automated machine 174 is registered with respect to the fixture location 118 as described herein. The known (e.g., changed) geometry of the workpiece 170 and the known position of the workpiece 170 relative to the fixture 102 are incorporated into and accounted for in the programmed toolpath of the second automated machine 174. Thus, such changes to the workpiece geometry 268 are accounted for in subsequent positioning and registration operations, thus enabling repeatable registration based on the position of the fixture 102.

[0037] Thus, the example registration apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 disclosed herein allow the workpiece 170 to be quickly and accurately positioned without requiring costly and time-consuming setup or positioning processes. Similarly, the automated machine 128 can be quickly and accurately registered to the fixture 102, and thus the workpiece 170, based on the determined position of the fixture 102.

[0038] 1-29 schematically illustrate various implementations of the interface device 220 and the correspondence mechanism 104 of the disclosed correspondence apparatus 100. As shown in FIGS. 1-10, the interface device 220 includes at least one gripper 108 that provides a contact interface with the correspondence mechanism 104. As shown in FIGS. 11-21, in one example, the interface device 220 includes at least one sensor 184 that provides a contactless interface with the correspondence mechanism 104. As shown in FIGS. 22-29, in one example, the interface device 220 includes multiple probes 202 that provide a contact interface with the correspondence mechanism 104.

[0039] 1, and particularly, FIGS. 2-4, in one example, the registration apparatus 100 includes a fixture 102. The fixture 102 is movable relative to a work cell 106. The registration apparatus 100 also includes a registration mechanism 104. The registration mechanism 104 is fixed relative to the fixture 102. For example, the registration mechanism 104 is coupled to the fixture 102. In one example, the registration mechanism 104 extends from the fixture 102.

[0040] 2-5, the mating mechanism 104 is coupled to and extends from the front end of the fixture 102. In other examples, the mating mechanism 104 is coupled to or disposed on another portion of the fixture 102 (e.g., a side, back, or bottom surface of the fixture 102).

[0041] In one example, the registration apparatus 100 includes a gripper 108. The gripper 108 is movable relative to the work cell 106 and the fixture 102. The gripper 108 is configured to engage (e.g., physically contact) the registration mechanism 104. The registration mechanism 104 is suitably positioned relative to the fixture 102 such that at least a portion of the registration mechanism 104 is physically accessible by the gripper 108. Conversely, the gripper 108 is suitably positioned relative to the fixture 102 such that at least a portion of the gripper 108 is physically accessible by the registration mechanism 104. With the gripper 108 engaged with the registration mechanism 104, the position of the gripper 108 (also referred to herein as a gripper position 114) ( FIG. 1 ) represents or corresponds to the registration mechanism position 116 ( FIG. 1 ). In other words, the gripper 108 positions the registration mechanism 104 within the reference frame 216.

[0042] 2-6 , in one example, gripper 108 includes an articulation mechanism 230 and a gripping head 232 coupled to a working end of articulation mechanism 230. Articulation mechanism 230 has multiple degrees of freedom and is configured to move gripping head 232 in three-dimensional space, such as linearly along at least one axis of fixed coordinate system 112 and / or rotationally about at least one axis of fixed coordinate system 112.

[0043] The gripping head 232 is configured to engage the registration mechanism 104. For example, the gripping head 232 is configured to grasp or otherwise securely hold at least a portion of the registration mechanism 104. With the gripping head 232 engaged with the registration mechanism 104, the gripper position 114 is a position of the gripping head 232 that represents or corresponds to the registration mechanism position 116.

[0044] The articulation mechanism 230 includes at least one suitable drive motor (not shown), such as an electromechanical motor, a pneumatic motor, or a hydraulic motor, that drives the movement of the articulation mechanism 230. The articulation mechanism 230 is also configured to provide position data (e.g., interface data 222) that represents the gripper position 114 in at least one dimension of the fixed coordinate system 112, e.g., relative to the frame of reference 216. For example, the articulation mechanism 230 also includes at least one encoder (not shown) and / or at least one sensor (not shown) that converts the movement of the articulation mechanism 230 into an electrical signal that represents the gripper position 114. The articulation mechanism 230 also includes other suitable electronic, mechanical, pneumatic, and hydraulic components (not shown). The articulation mechanism 230 operates under computer control, such as by the controller 110.

[0045] 2 and 4, in one example, articulation mechanism 230 is coupled to or forms a part of automated machine 128. In FIG. 4, the robotic arm 226 and end effector 228 (FIG. 2) of automated machine 128 (e.g., for performing at least one manufacturing process) have been removed for clarity. In this example, automated machine 128 is configured to move gripper 108 relative to work cell 106 and fixture 102 in at least one dimension of fixed coordinate system 112. In other words, at least a portion of the range of motion, i.e., one or more degrees of freedom, of articulation mechanism 230 is provided by automated machine 128.

[0046] 5, in one example, the articulation mechanism 230 is separate and independent from the automated machine 128. In this example, the full range of motion or degrees of freedom of the gripper 108 are provided by (e.g., inherent to) the articulation mechanism 230.

[0047] 6, in another example of an association apparatus 100, interface device 220 (FIG. 1) includes two or more grippers 108 (referred to herein as a plurality of grippers 108). In this example, association apparatus 100 includes two or more association mechanisms 104 (referred to herein as a plurality of association mechanisms 104). Each of the association mechanisms 104 is fixed relative to fixture 102. Each of grippers 108 is configured to engage and position a corresponding one of the association mechanisms 104.

[0048] 1-6 , the registration apparatus 100 also includes a controller 110. The controller 110 is in communication with the gripper 108. The controller 110 is configured to position the fixture 102 relative to the work cell 106 (e.g., relative to the reference frame 216) from a gripper position 114 of the gripper 108 when the gripper 108 is engaged with the registration mechanism 104.

[0049] In one example, the controller 110 is configured to determine a gripper position 114 of the gripper 108 in at least one dimension of the fixed coordinate system 112, e.g., relative to the frame of reference 216. The controller 110 is also configured to determine, from the gripper position 114 of the gripper 108, a reference mechanism position 116 of the reference mechanism 104 in at least one dimension of the fixed coordinate system 112, e.g., relative to the frame of reference 216. The controller 110 is further configured to determine, from the reference mechanism position 116 of the reference mechanism 104, a fixture position 118 of the fixture 102 in at least one dimension of the fixed coordinate system 112, e.g., relative to the frame of reference 216.

[0050] In one example, the controller 110 is configured to register a digital model 120 ( FIG. 1 ) representing the fixture 102 and the reference feature 104 to a reference feature location 116 of the reference feature 104. The controller 110 is also configured to convert a model location 126 of the digital model 120 registered to the reference feature location 116 to a fixture location 118 of the fixture 102.

[0051] 7 schematically illustrates an example of inputs 234 provided to and outputs 236 generated by the controller 110 during the positioning and registration process. In one example, gripper position data 238 is provided to the controller 110 by the gripper 108. The gripper position data 238 is an example of interface data 222 (FIG. 1). In one example, the gripper position data 238 is generated by an encoder, a sensor, another relative positioning device, or a combination thereof, and represents the actual physical position of the gripper 108 (gripper position 114) relative to the frame of reference 216 (FIG. 3). The controller 110 processes the gripper position data 238 and determines the gripper position 114 based on the gripper position data 238. The controller 110 then processes the gripper position 114 and determines the registration mechanism position 116 based on the gripper position 114.

[0052] 2-6 , in one example, with the gripper 108 (e.g., gripping head 232) engaged with the association mechanism 104, there is at least one contact point between the gripper 108 and the association mechanism 104. This contact point has X, Y, and Z coordinates that are common to both the gripper 108 and the association mechanism 104. Gripper position data 238 ( FIG. 16 ) represents the X, Y, and Z coordinates of the contact point of the gripper 108, and the gripper position 114 is described by the X, Y, and Z coordinates of the contact point of the gripper 108. The controller 110 converts the X, Y, and Z coordinates of the contact point of the gripper 108 into the X, Y, and Z coordinates of the corresponding contact point of the association mechanism 104. The controller 110 then determines the association mechanism position 116, which is described by the X, Y, and Z coordinates of the contact point of the association mechanism 104.

[0053] In one example, the gripper 108 (e.g., gripping head 232) and the matching mechanism 104 include multiple contact points. Thus, the gripper position 114 is described by the X, Y, and Z coordinates of the multiple contact points of the gripper 108, and the matching mechanism position 116 is described by the X, Y, and Z coordinates of the corresponding multiple contact points of the matching mechanism 104.

[0054] It should be noted that increasing the number of contact points between the gripper 108 and the registration mechanism 104 provides a greater number of XYZ coordinate data points for processing, resulting in greater accuracy of the registration mechanism position 116 and the fixture position 118 during alignment of the data points in the registration process. In one example, the gripper 108 (e.g., gripping head 232) and the registration mechanism 104 include at least three contact points.

[0055] 8A, 8B, 9A, and 9B, in one example, the gripper 108 (e.g., the gripping head 232) includes at least one contact-index 148 (FIGS. 8A and 9A), and the mating mechanism 104 includes at least one interface-index 146 (FIGS. 8B and 9B). When the gripper 108 (e.g., the gripping head 232) engages the mating mechanism 104, the contact-index 148 engages the interface-index 146 such that there is at least one contact point between the contact-index 148 and the interface-index 146. This contact point has X, Y, and Z coordinates that are common to both the contact-index 148 and the interface-index 146. The gripper position data 238 represents the X, Y, and Z coordinates of the contact point of the contact-index 148, and the gripper position 114 is described by the X, Y, and Z coordinates of the contact point of the contact-index 148.

[0056] The controller 110 converts the XYZ coordinates of the contact point on the contact indicator 148 into the XYZ coordinates of the corresponding contact point on the interface indicator 146. The controller 110 determines the mapping feature position 116 described by the XYZ coordinates of the contact point on the interface indicator 146.

[0057] Generally, gripper 108 (e.g., gripping head 232) includes multiple contact indicators 148 and mapping mechanism 104 includes multiple interface indicators 146, resulting in multiple contact points. Thus, gripper position data 238 (FIG. 7) represents the X, Y, and Z coordinates of the multiple contact points of contact indicators 148 of gripper 108. Gripper position 114 is described by the X, Y, and Z coordinates of the contact points of contact indicators 148 of gripper 108. Mapped mechanism position 116 is described by the X, Y, and Z coordinates of the corresponding multiple contact points of interface indicators 146.

[0058] In one example, the gripper 108 (e.g., gripping head 232) includes at least three contact indicators 148 and the association mechanism 104 includes at least three interface indicators 146, resulting in at least three points of contact. In other examples, the gripper 108 (e.g., gripping head 232) may include a fewer or greater number of contact indicators 148 and the association mechanism 104 may include a fewer or greater number of interface indicators 146.

[0059] It should be noted that increasing the number of contact indicators 148 and interface indicators 146 increases the number of contact points between the gripper 108 and the registration mechanism 104, resulting in a greater number of XYZ coordinate data points for processing, thereby increasing the accuracy of the registration mechanism position 116 and fixture position 118 during alignment of the data points in the registration process.

[0060] 7 , the controller 110 is configured to register the digital model 120 representing the fixture 102 and the reference feature 104 to the reference feature location 116 to determine the model location 126. In one example, the controller 110 is configured to register and align the digital model 120 with X, Y, and Z coordinates describing the reference feature location 116 within the reference frame 216. The digital model 120 includes data points representing contact points of the reference feature 104. For example, the digital model 120 includes data points representing the interface indicator 146 of the reference feature 104. In one example, the controller 110 performs a best-fit process (e.g., executes a best-fit algorithm) to align the data points representing the contact points of the reference feature 104, such as the data points representing the interface indicator 146, with the data points representing the X, Y, and Z coordinates describing the reference feature location 116. In one example, the best-fit process includes a rigid body, point cloud transformation operation.

[0061] With the digital model 120 registered and aligned with the associated feature positions 116, the controller 110 is configured to transform the model positions 126 into fixture positions 118 of the fixture 102, for example, relative to the frame of reference 216. For example, the fixture positions 118 are assumed to be the same as the model positions 126 within a tolerance. Thus, the fixture positions 118 represent the most recent (e.g., current, real-time) positions of the fixture 102, and thus the workpiece 170, relative to the work cell 106 and automated machine 128.

[0062] When the fixture location 118 is known, the automated machine 128 is mapped or "zeroed" to the fixture location 118 and performs a manufacturing process on the workpiece 170 according to a predetermined toolpath. Based on the fixture location 118, the automated machine 128 is mapped to the fixture 102, and consequently, the automated machine 128 is mapped to the workpiece 170. The geometry of the workpiece 170 and the known position of the workpiece 170 relative to the fixture 102 are incorporated into and accounted for by the programmed toolpath of the automated machine 128.

[0063] 1 and 2, in one example, the mapping apparatus 100 includes an automated machine 128. The automated machine 128 is disposed within the work cell 106 and is in communication with the controller 110. The controller 110 is configured to map the automated machine 128 to a fixture position 118 of the fixture 102.

[0064] 2 and 4-6 , in one example, the automated machine 128 includes a gantry 134. The gantry 134 is configured to provide at least a portion of the range of motion, i.e., one or more degrees of freedom, of the automated machine 128. In one example, the robotic arm 226 is coupled to the gantry 134. In one example, the gantry 134 is an overhead gantry that is movable within the work cell 106 to move the robotic arm 226 in at least one dimension of the fixed coordinate system 112. In this example, the fixture 102, and thus the workpiece 170, is moved to a work position 258 within the work cell 106, and the gantry 134 and / or the robotic arm 226 moves relative to the fixture 102 such that the end effector 228 follows a predetermined toolpath.

[0065] In another example (not shown), the robot arm 226 is a freestanding robot with a fixed base within the work cell 106. In this example, the fixture 102, and therefore the workpiece 170, is moved to a work position 258 within the work cell 106, and the robot arm 226 moves relative to the fixture 102 such that the end effector 228 follows a predetermined toolpath.

[0066] Although the illustrated example of the alignment apparatus 100 shows only one automated machine 128 (e.g., one robotic arm 226 with one end effector 228) for performing manufacturing processes on the workpieces 170 in the work cell 106, in other examples, the alignment apparatus 100 may have any number of additional automated machines 128 (e.g., additional robotic arms 226 and / or additional end effectors 228).

[0067] 1 and 2, in one example, the manufacturing process includes a pre-cured composite assembly process or other additive processing process performed on a pre-cured composite material, such as a composite layup process and / or a composite lamination process. In this example, the workpiece 170 includes a pre-cured composite layup (e.g., a pre-impregnated composite layup). The fixture 102 includes or takes the form of a mandrel 130. The mandrel 130 is configured to support the composite layup (workpiece 170). The automated machine 128 is configured to perform the pre-cured manufacturing process on the composite layup (workpiece 170). For example, the automated machine 128 includes or takes the form of an automated fiber placement machine 132 (FIG. 1).

[0068] In one or more other examples, the manufacturing process includes other additive manufacturing processes, such as assembly processes, or subtractive manufacturing processes, such as machining. In such examples, workpiece 170 is one of a post-cure composite structure, a metal structure, a plastic structure, or another non-composite structure. Fixture 102 includes at least one holding mechanism 260 ( FIG. 1 ) configured to secure workpiece 170 to fixture 102 during transfer to work cell 106 and during the manufacturing process. Automated machine 128 is configured to perform at least one of an additive manufacturing process and a subtractive manufacturing process on workpiece 170. In one example, automated machine 128 is configured to perform a post-cure manufacturing process on a post-cure composite structure. For example, automated machine 128 may include or take the form of any suitable machine tool 270 ( FIG. 1 ).

[0069] In one or more examples, any one of the various manufacturing steps described herein is part of a continuous flow manufacturing process. For example, the fixture 102 and workpiece 170 are pulsed into one of a plurality of work cells forming a continuous flow manufacturing system. In any one of the plurality of work cells, the manufacturing step forms part of the continuous flow manufacturing process. In one example, the manufacturing step includes placing one or more plies of pre-cured composite material to partially form a composite layup. In one example, the manufacturing step includes assembling or placing a secondary structure onto a post-cured composite structure or a non-composite structure. In one example, the manufacturing step includes machining one or more features of a post-cured composite structure or a non-composite structure.

[0070] In one example, the fixture 102 is moved to the work position 258, and the immediate location of the fixture 102 and the workpiece 170 (e.g., fixture position 118) is determined using the gripper 108 and the registration mechanism 104, as described above. Based on the fixture position 118 (e.g., the position of the fixture 102 and the position of the workpiece 170 relative to the fixture 102), the automated fiber placement machine 132 lays and / or compacts at least a portion of at least one layer of the stack of composite laminations.

[0071] 2 and 4-6, in one example, the alignment apparatus 100 includes a drive assembly 138 coupled to the gripper 108. The drive assembly 138 is configured to move the gripper 108 relative to the frame of reference 216, e.g., in at least one dimension of the fixed coordinate system 112. In one example, the drive assembly 138 is coupled to or forms part of the articulation mechanism 230 of the gripper 108, such as in an example where the gripper 108 is separate from the automated machine 128, as illustrated in FIGS. 5 and 6. In another example, the drive assembly 138 is coupled to or formed by the automated machine 128, such as in an example where the gripper 108 is coupled to the automated machine 128, as illustrated in FIGS. 2 and 4.

[0072] 1 , in one example, gripper 108 is configured to move fixture 102 within work envelope 140 of work cell 106. In one example, fixture 102 and workpiece 170 are moved to an initial pre-work position, such as a position (e.g., outside work cell 106) that is proximate (e.g., at or near) work location 258. Gripper 108, operating under computer control, moves to engage with registration mechanism 104. While engaged with registration mechanism 104, gripper 108 moves fixture 102 and workpiece 170 to work location 258 (e.g., inside work cell 106). In this manner, fixture 102 and workpiece 170 are moved to work location 258 while fixture position 118 is determined as described above. This combined process further improves the cycle time of the manufacturing process by allowing the steps of moving the fixture 102 and workpiece 170 and positioning the fixture 102 and workpiece 170 to be performed substantially simultaneously.

[0073] In another example, the mapping apparatus 100 includes an independent movement mechanism (not shown) that is separate from the gripper 108 and configured to move the fixture 102 to the work position 258. In this example, the fixture 102 and workpiece 170 are moved to a pre-work position, and the independent movement mechanism, operating under computer control, moves the fixture 102 and workpiece 170 to the work position 258.

[0074] FIGS. 8A, 8B, 9A, and 9B schematically illustrate examples of gripper 108 and engagement mechanism 104. In one example, gripper 108 (e.g., grip head 232) includes jaw assembly 144 ( FIGS. 8A and 9A ). Jaw assembly 144 is configured to grasp, grip, clamp, or otherwise securely hold at least a portion of engagement mechanism 104 ( FIGS. 8B and 9B ). In one example, engagement mechanism 104 includes plate 150 coupled to fixture 102 (not shown in FIG. 8B ) and extending therefrom. Contact indicator 148 ( FIGS. 8A and 9A ) and interface indicator 146 ( FIGS. 8B and 9B ) are configured to contact and mate with each other when gripper 108 (e.g., jaw assembly 144) properly engages engagement mechanism 104 (e.g., plate 150).

[0075] 8A and 8B , in one example, jaw assembly 144 includes a first jaw and a second jaw. The first jaw and second jaw are movable relative to one another to selectively engage (e.g., grasp) plate 150. In one example, jaw assembly 144 includes a first (e.g., upper) jaw that is stationary and a second (e.g., lower) jaw that is movable relative to the first jaw. In one example, each jaw of jaw assembly 144 has a substantially planar engagement surface configured to securely contact a corresponding one of the opposing planar engagement surfaces of plate 150. Other configurations of jaw assembly 144 and plate 150 are also contemplated.

[0076] In one example, contact indicator 148 ( FIG. 8A ) is coupled to or disposed on jaw assembly 144, and interface indicator 146 ( FIG. 8B ) is coupled to or disposed on plate 150. Contact indicator 148 is appropriately positioned and configured to engage interface indicator 146 when jaw assembly 144 grasps plate 150. In one example, contact indicator 148 is positioned on and protrudes from an engagement surface of one of the jaws (e.g., the upper jaw) of jaw assembly 144, and interface indicator 146 is positioned on and protrudes from one of the engagement surfaces of plate 150.

[0077] In one example, contact indicator 148 includes or takes the form of at least one contact structure 154. Interface indicator 146 includes or takes the form of at least one interface structure 152. In one example, interface structure 152 and contact structure 154 have complementary geometric shapes and dimensions such that corresponding surfaces of contact structure 154 (e.g., forming contact indicator 148) and interface structure 152 (e.g., forming interface indicator 146) are in contact when grip head 232 properly engages registration mechanism 104. Contact structure 154 and interface structure 152 each include or take the form of any one of a variety of structural configurations or arrangements.

[0078] In one example, the contact structure 154 and the interface structure 152 include or take the form of a plurality of cooperating complementary point structures. In the illustrated example, the contact structure 154 includes or takes the form of a protrusion formed on (e.g., protruding from) the surface of the grip head 232, and the interface structure 152 includes or takes the form of an opening formed on (e.g., arising from) the surface of the plate 150. In this example, the interface structure 152 is configured to receive and mate with at least a portion of the contact structure 154. In another example, this arrangement may be reversed. For example, the contact structure 154 includes or takes the form of an opening, and the interface structure 152 includes or takes the form of a protrusion. By way of example, the protrusion may be or take the form of a pin, spring-loaded ball bearing, or other protrusion, and the opening may be or take the form of a hole, detent, recess, or other opening.

[0079] 9A and 9B, in another example, the interface structure 152 of the interface index portion 146 includes or takes the form of a tooling ball that protrudes from the plate 150. The contact structure 154 of the contact index portion 148 includes or takes the form of a cooperating guide hole that is formed by the jaw assembly 144 and configured to receive and mate with the tooling ball when the grip head 232 properly engages the plate 150. In another example, this arrangement may be reversed. For example, the contact structure 154 includes or takes the form of a tooling ball and the interface structure 152 includes or takes the form of a guide hole.

[0080] Other structural configurations and / or arrangements of the contact index portion 148 (e.g., contact structure 154) and interface index portion 146 (e.g., interface structure 152) are also contemplated, such as cooperating complementary cup and cone configurations.

[0081] In general, any suitable configuration or arrangement of contact indicators 148 and interface indicators 146 may be used such that there are at least three contact points between gripper 108 and registration mechanism 104 that can be used to generate at least three data points representing at least three X, Y, and Z coordinates of registration mechanism 104. In most cases, three data points are sufficient to generate a complete three-dimensional position of fixture 102 during the positioning and registration process described above.

[0082] In one example, the XZY coordinate positions of at least two contact indicators 148 (e.g., at least two contact structures 154) differ in at least two dimensions of fixed coordinate system 112. Similarly, the XZY coordinate positions of at least two interface indicators 146 (e.g., at least two interface structures 152) differ in at least two dimensions of fixed coordinate system 112.

[0083] In an exemplary implementation of the above-described positioning and registration process, the fixture 102, and thus the workpiece 170, is moved to a working position 258 for engagement of the registration feature 104 by the gripper 108. With the fixture 102 in the working position 258, the position of the registration feature 104 relative to the reference frame 216 is approximately known or estimated within an acceptable tolerance, allowing the gripper 108 to be moved under computer control to a pre-engagement position for the registration feature 104. The controller 110 then performs a search process in which the gripper 108 moves incrementally along a predefined search path to find the interface indicator 146 and align and mate the contact indicator 148 with the interface indicator 146. Once the contact indicator 148 and the interface indicator 146 are properly aligned and mated with each other, the contact indicator 148 and the interface indicator 146 share a contact point, and the positioning and registration process is performed as described above.

[0084] 8A and 9A, in one example, gripper 108 includes at least one engagement sensor 240. Engagement sensor 240 is configured to determine when gripper 108 is properly aligned and engaged with mapping mechanism 104 (e.g., when contact indicator 148 and interface indicator 146 are properly aligned and mated with one another). Engagement sensor 240 may include or take the form of any one of various types of suitable sensors, such as a depth gauge, a pressure sensor, a tooling probe, a displacement sensor, or the like.

[0085] 1-6 , in one example, the registration apparatus 100 includes a vehicle 160. The vehicle 160 is configured to support the fixture 102. The vehicle 160 is configured to move the fixture 102 relative to the work cell 106. In one example, the vehicle 160 is configured to move the fixture 102, and thus the workpiece 170, to a work position 258 where the gripper 108 engages the registration mechanism 104 to perform the positioning and registration steps described above. In another example, the vehicle 160 is configured to move the fixture 102, and thus the workpiece 170, to a pre-work position relative to the work cell 106 where the gripper 108 engages the registration mechanism 104 to perform the moving, positioning, and registration steps described above.

[0086] 1 , in one example, vehicle 160 includes or takes the form of an automated guided vehicle 162. The automated guided vehicle 162 is configured to move autonomously along a predetermined path of travel under computer control. In this example, work cell 106 may include one or more of sensors, guide tapes, guide wires, laser targets, and any other suitable navigation mechanisms for navigating the automated guided vehicle 162 along the predetermined path of travel. In this example, the automated guided vehicle 162 moving along the predetermined path of travel is configured to move fixture 102 to a work position 258 (or pre-work position) for gripper 108 to locate and engage association mechanism 104, as described above.

[0087] 1 and 2, in one example, vehicle 160 includes or takes the form of a cart 164. Cart 164 is configured to move along a track 166 through work cell 106. In this example, cart 164 moving along track 166 is configured to move fixture 102 to work position 258 (or pre-work position) for gripper 108 to locate and engage association mechanism 104, as described above.

[0088] In one example, the track 166 is positioned so that the Z coordinate of the fixture 102, and therefore the registration mechanism 104, is fixed and remains constant as the cart 164 moves along the track 166 to the work position 258. In this example, the positioning process performed by the gripper 108 need only determine the XY coordinates of the contact point between the gripper 108 and the registration mechanism 104.

[0089] 1 and 2 , in one example, manufacturing system 168 includes work cell 106 and automated machine 128. Automated machine 128 is disposed within work cell 106 and configured to perform at least one manufacturing process. Manufacturing system 168 also includes fixture 102. Fixture 102 is configured to support workpiece 170 and is movable relative to work cell 106. Manufacturing system 168 further includes association mechanism 104. Association mechanism 104 is fixed relative to fixture 102. For example, association mechanism 104 is coupled to fixture 102.

[0090] The manufacturing system 168 also includes a gripper 108. The gripper 108 is configured to engage the association mechanism 104. The manufacturing system 168 further includes a controller 110. The controller 110 is in communication with the gripper 108 and the automated machine 128. The controller 110 is configured to position the fixture 102 relative to the work cell 106 from a gripper position 114 of the gripper 108 engaged with the association mechanism 104. The controller 110 is also configured to associate the automated machine 128 with the fixture position 118 of the fixture 102.

[0091] 1 and 7 , in an example manufacturing system 168, a controller 110 is configured to determine a gripper position 114 of a gripper 108 in at least one dimension of a fixed coordinate system 112. The controller 110 is also configured to determine a reference feature position 116 of a reference feature 104 in at least one dimension of the fixed coordinate system 112 from the gripper position 114 of the gripper 108. The controller 110 is further configured to determine a fixture position 118 of a fixture 102 in at least one dimension of the fixed coordinate system 112 from the reference feature position 116 of the reference feature 104. The controller 110 is also configured to register a digital model 120 representing the fixture 102 and the reference feature 104 to the reference feature position 116 of the reference feature 104, and to transform a model position 126 of the digital model 120 registered to the reference feature position 116 to the fixture position 118 of the fixture 102.

[0092] 1-3 , in an example manufacturing system 168, the fixture 102 includes a mandrel 130 configured to support a composite layup, and the automated machine 128 includes an automated fiber placement machine 132 configured to perform at least one composite layup or lamination process.

[0093] 2 and 4, in an example manufacturing system 168, the gripper 108 is coupled to an automated machine 128 that is configured to move the gripper 108 relative to the frame of reference 216 in at least one dimension of the fixed coordinate system 112. With reference to FIGS. 5 and 6, in one example, the gripper 108 is configured to move independently of the automated machine 128. With reference to FIGS. 2-6, in one example, the gripper 108 is configured to move the fixture 102 within the work envelope 140 of the work cell 106.

[0094] 8A, 8B, 9A, and 9B, in an example manufacturing system 168, the mapping mechanism 104 includes at least one interface indicator 146. The gripper 108 includes at least one contact indicator 148 configured to engage the at least one interface indicator 146.

[0095] 1-6, in one example, manufacturing system 168 includes vehicle 160. Vehicle 160 is configured to support fixture 102 and move fixture 102 relative to work cell 106.

[0096] 1 and 2, in one example, manufacturing system 168 also includes a track 166. Track 166 passes through work cell 106. In this example, vehicle 160 includes or takes the form of a cart 164 configured to move along track 166.

[0097] 10 , in one example, manufacturing system 168 includes a second work cell 172. Manufacturing system 168 also includes a second automated machine 174. Second automated machine 174 is disposed within second work cell 172 and is configured to perform at least one manufacturing process on workpiece 170.

[0098] The manufacturing system 168 further includes a second gripper 176. The second gripper 176 is configured to engage the association mechanism 104. The controller 110 is in communication with the second gripper 176 and the second automated machine 174. The controller 110 is configured to position the fixture 102 relative to the second work cell 172 from a second gripper position 178 of the second gripper 176 engaged with the association mechanism 104. The controller 110 is further configured to associate the second automated machine 174 with a second fixture position 180 of the fixture 102. Once associated, the second automated machine 174 performs at least one manufacturing operation on the workpiece 170.

[0099] 1 and, in particular, FIGS. 11-13, an alignment apparatus 100 includes a fixture 102. The fixture 102 is movable relative to a work cell 106. The opening 100 also includes an alignment mechanism 104. The alignment mechanism 104 is fixed relative to the fixture 102. For example, the alignment mechanism 104 is disposed on the fixture 102.

[0100] 11-15, the mating mechanism 104 is coupled to or disposed on the top of the fixture 102. In other examples, the mating mechanism 104 is coupled to or disposed on another portion of the fixture 102 (e.g., the side, front, back, bottom, etc.).

[0101] In one example, the alignment device 100 includes a sensor 184. The sensor 184 is configured to detect (e.g., visually identify) the alignment feature 104. The alignment feature 104 is appropriately positioned relative to the fixture 102 such that at least a portion of the alignment feature 104 is visually accessible by the sensor 184. Conversely, the sensor 184 is appropriately positioned relative to the fixture 102 such that at least a portion of the sensor 184 is physically accessible by the alignment feature 104. In one example, the alignment feature 104 is disposed on or formed within an exposed outer surface of the fixture 102. The sensor 184 is configured to generate sensor data 186 ( FIG. 1 ) representing the position of the alignment feature 104 (alignment feature position 116) ( FIG. 1 ). In other words, the sensor 184 locates the alignment feature 104 within the reference frame 216.

[0102] 11-13, in one example, the sensor 184 includes an articulating mechanism 230 and a sensor head 242 coupled to a working end of the articulating mechanism 230. The articulating mechanism 230 is configured to move the sensor head 242 in three-dimensional space, such as linearly along at least one axis of the fixed coordinate system 112 and / or rotationally about at least one axis of the fixed coordinate system 112.

[0103] The articulation mechanism 230 is also configured to provide position data (e.g., interface data 222) (FIG. 1) that represents the position of the sensor 184 (e.g., sensor head 242) relative to the frame of reference 216. In one example, the position data and the sensor data 186 are used to determine the associated mechanism position 116 relative to the frame of reference 216. In one example, and for purposes of this specification, the position data of the sensor 184 relative to the frame of reference 216 is incorporated with the sensor data 186.

[0104] 13 , sensor head 242 includes or takes the form of any one of a variety of machine vision or computer vision systems configured to scan fixture 102 and identify correlation feature 104 from the scan. In one example, sensor 184 (e.g., sensor head 242) includes or takes the form of a camera configured to capture still images or video (e.g., sensor data 186) visually representative of fixture 102 and correlation feature 104. In another example, sensor 184 (e.g., sensor head 242) includes or takes the form of a laser scanner configured to project a laser light at fixture 102, collect back-polarized laser light from fixture 102, and generate sensor data 186 from the collected laser light representative of correlation feature 104.

[0105] In one example, the sensor data 186 represents or corresponds to the matching mechanism position 116. In one example, the laser scanner is a two-dimensional laser scanner, and the sensor data 186 represents the position of the matching mechanism 104 in two dimensions (e.g., XY coordinates) of a fixed coordinate system. In another example, the laser scanner is a three-dimensional scanner, and the sensor data 186 represents the position of the matching mechanism in three dimensions (e.g., XYZ coordinates) of a fixed coordinate system.

[0106] 11 and 12 , in one example, articulation mechanism 230 is coupled to or forms a part of automated machine 128. In FIG. 12 , the robotic arm 226 and end effector 228 ( FIG. 11 ) of automated machine 128 (e.g., for performing at least one manufacturing process) have been removed for clarity. In this example, automated machine 128 is configured to move sensor 184 relative to work cell 106 and fixture 102 in at least one dimension of fixed coordinate system 112. In other words, at least a portion of the range of motion, i.e., one or more degrees of freedom, of articulation mechanism 230 is provided by automated machine 128.

[0107] 13, in one example, the articulation mechanism 230 is separate and independent from the automated machine 128. In this example, the full range of motion, i.e., all degrees of freedom, of the sensor 184 is provided by (e.g., inherent to) the articulation mechanism 230.

[0108] 14 , in another example of correlation apparatus 100, interface device 220 (FIG. 1) includes two or more sensors 184 (herein referred to as a plurality of sensors 184). In this example, correlation apparatus 100 includes two or more correlation mechanisms 104 (e.g., a plurality of correlation mechanisms 104). Each of correlation mechanisms 104 is fixed relative to fixture 102. Each of sensors 184 is configured to scan, detect, and locate at least a portion of correlation mechanism 104 or a corresponding one of the plurality of correlation mechanisms 104.

[0109] 1 and 11-15, the registration apparatus 100 also includes a controller 110. The controller 110 is in communication with the sensor 184. The controller 110 is configured to position the fixture 102 relative to the work cell 106 from a registration mechanism position 116 of the registration mechanism 104, as identified by the sensor 184.

[0110] In one example, controller 110 is configured to determine, from sensor data 186 generated by sensor 184, a reference feature position 116 of reference feature 104 in at least one dimension of fixed coordinate system 112, e.g., relative to frame of reference 216. Controller 110 is also configured to determine, from reference feature position 116 of reference feature 104, a fixture position 118 of fixture 102 in at least one dimension of fixed coordinate system 112, e.g., relative to frame of reference 216.

[0111] In one example, the controller 110 is configured to register a digital model 120 ( FIG. 1 ) representing the fixture 102 and the reference feature 104 to a reference feature location 116 of the reference feature 104. The controller 110 is also configured to convert a model location 126 of the digital model 120 registered to the reference feature location 116 to a fixture location 118 of the fixture 102.

[0112] FIG. 16 schematically illustrates an example of inputs 234 provided to and outputs 236 generated by the controller 110 during the positioning and registration process. In one example, sensor data 186 is provided to the controller 110 from the sensor 184. The sensor data 186 is an example of interface data 222 (FIG. 1). In one example, the sensor data 186 (e.g., interface data 222) also includes position data representing the actual physical position of the sensor 184 (e.g., sensor head 242) (FIG. 13) relative to the frame of reference 216, such as generated by an encoder, a sensor, other relative position information device, or a combination thereof. The controller 110 processes the sensor data 186 and determines the registration mechanism position 116 based on the sensor data 186.

[0113] 11-15 , in one example, sensor 184 (e.g., sensor head 242) moves along a scan path relative to fixture 102 to scan at least a portion of fixture 102, including matching feature 104. Sensor 184 may collect a sufficient number of data points of sensor data 186 ( FIG. 16 ) to locate matching feature 104 in a single pass, or may require two or more passes. Controller 110 is configured to identify and extract the data points representing matching feature 104. Controller 110 then determines the X, Y, and Z coordinates of the data points representing matching feature 104 relative to frame of reference 216. Controller 110 then determines matching feature position 116, which is described by the X, Y, and Z coordinates of the data points representing matching feature 104 in sensor data 186.

[0114] The correspondence feature 104 comprises a structure that is visually perceptible and / or computationally distinguishable from the surface area surrounding the fixture 102. For example, the correspondence feature 104 comprises a structural configuration suitable for computer perception and recognition, such as in a point cloud processing step performed on multiple data points of the sensor data 186. The correspondence feature location 116 is described by the XYZ coordinates of multiple data points representing the correspondence feature 104 in the sensor data 186.

[0115] It should be noted that increasing the number of data points representing the matching feature 104 in the sensor data 186 provides a greater number of XYZ coordinate data points for processing, resulting in greater accuracy of the matching feature position 116 and fixture position 118 during data point alignment in the matching process.

[0116] The controller 110 is configured to register the digital model 120 representing the fixture 102 and the reference feature 104 to the reference feature location 116 to determine the model location 126. In one example, the controller 110 is configured to register and align the digital model 120 with X, Y, and Z coordinates describing the reference feature location 116 within the reference frame 216. The digital model 120 includes data points representing the reference feature 104. In one example, the controller 110 performs a best-fit process (e.g., executes a best-fit algorithm) to align the data points representing the reference feature 104 with the data points representing the X, Y, and Z coordinates describing the reference feature location 116. In one example, the best-fit process includes a rigid point cloud transformation process.

[0117] With the digital model 120 registered and aligned with the associated feature positions 116, the controller 110 is configured to transform the model positions 126 into fixture positions 118 of the fixture 102, for example, relative to the frame of reference 216. For example, the fixture positions 118 are assumed to be the same as the model positions 126 within a tolerance. Thus, the fixture positions 118 represent the most recent (e.g., current, real-time) positions of the fixture 102, and thus the workpiece 170, relative to the work cell 106 and automated machine 128.

[0118] When the fixture location 118 is known, the automated machine 128 is mapped or "zeroed" to the fixture location 118 and performs a manufacturing process on the workpiece 170 according to a predetermined toolpath. Based on the fixture location 118, the automated machine 128 is mapped to the fixture 102, and consequently, the automated machine 128 is mapped to the workpiece 170. The geometry of the workpiece 170 and the known position of the workpiece 170 relative to the fixture 102 are incorporated into and accounted for by the programmed toolpath of the automated machine 128.

[0119] 1 and 11 , in one example, the mapping apparatus 100 includes an automated machine 128. The automated machine 128 is located within the work cell 106 and is in communication with the controller 110. The controller 110 is configured to map the automated machine 128 to a fixture position 118 of the fixture 102.

[0120] 11, 12, 14, and 15, in one example, the automated machine 128 includes a gantry 134. In this example, the fixture 102, and thus the workpiece 170, is moved to a work position 258 within the work cell 106, and the gantry 134 and / or a robotic arm 226 coupled to the gantry 134 moves relative to the fixture 102 such that the end effector 228 follows a predetermined toolpath.

[0121] In another example (not shown), the robot arm 226 is a free-standing robot with a fixed base within the work cell 106. In this example, the fixture 102, and therefore the workpiece 170, is moved to a work position 258 within the work cell 106, and the robot arm 226 moves relative to the fixture 102 such that the end effector 228 follows a predetermined toolpath.

[0122] Although the illustrated example of the alignment apparatus 100 shows only one automated machine 128 (e.g., one robotic arm 226 with one end effector 228) for performing manufacturing processes on the workpieces 170 in the work cell 106, in other examples, the alignment apparatus 100 may have any number of additional automated machines 128 (e.g., additional robotic arms 226 and / or additional end effectors 228).

[0123] 1 and 11 , in one example, the manufacturing process includes a pre-cured composite assembly process, such as a composite layup process and / or a composite lamination process. In this example, the workpiece 170 includes a composite layup (e.g., a composite layup). The fixture 102 includes or takes the form of a mandrel 130. The mandrel 130 is configured to support the composite layup. The automated machine 128 includes or takes the form of an automated fiber placement machine 132.

[0124] In one example, the fixture 102 is moved to the work position 258, and the immediate location of the fixture 102 and the workpiece 170 (e.g., fixture position 118) is determined using the sensor 184 and the registration mechanism 104, as described above. Based on the fixture position 118 (e.g., the position of the fixture 102 and the position of the workpiece 170 relative to the position of the fixture 102), the automated fiber placement machine 132 lays and / or consolidates at least a portion of at least one layer of the stack of composite laminations.

[0125] In one or more other examples (not explicitly shown), the manufacturing process includes another assembly process or machining. In such examples, workpiece 170 may be a post-cure composite workpiece, a metal workpiece, a plastic workpiece, or other non-composite workpiece. Fixture 102 includes a suitable holding mechanism 260 ( FIG. 1 ) configured to secure workpiece 170 during transfer to work cell 106 and during the manufacturing process. Automated machine 128 may include or take the form of any suitable machine tool.

[0126] 12, 14, and 15, in one example, the registration apparatus 100 includes a drive assembly 138 coupled to the sensor 184. The drive assembly 138 is configured to move the sensor 184 (e.g., the sensor head 242) relative to the frame of reference 216, e.g., in one or more dimensions of the fixed coordinate system 112. In one example, the drive assembly 138 is coupled to or forms part of the articulation mechanism 230 of the sensor 184, such as in an example where the sensor 184 is separate from the automated machine 128, as shown in FIGS. 14 and 15. In another example, the drive assembly 138 is coupled to or formed by the automated machine 128, such as in an example where the sensor 184 is coupled to the automated machine 128, as shown in FIGS. 11 and 12.

[0127] In one example, the registration device 100 includes an independent movement mechanism (not shown) configured to move the fixture 102 to the work position 258 .

[0128] 13, in one example, the mapping mechanism 104 includes at least one interface structure 192. In the example shown in Figure 13, the mapping mechanism 104 includes two interface structures 192. However, in other examples, the mapping mechanism 104 includes any number of interface structures 192.

[0129] In one example, the interface structure 192 is disposed on a surface 194 (e.g., an exposed surface) of the fixture 102. In other words, the interface structure 192 is suitably positioned so that it is not covered or otherwise obscured by the workpiece 170 (not shown in FIG. 13 ) secured to the fixture 102. The interface structure 192 is suitably positioned so that it is visually accessible by the sensor 184 during the positioning and registration process described above. The interface structure 192 may include any one of a variety of different structures that are visually perceptible and / or computationally distinguishable from the surface 194 of the fixture 10 that surrounds the registration mechanism 104. FIGS. 17-20 schematically illustrate various examples of the interface structure 192.

[0130] 17, in one example of the mating mechanism 104, the interface structure 192 is continuous and extends longitudinally along a surface 194 (e.g., the top surface) of the fixture 102. In other words, the interface structure 192 may be a continuous interface structure. In one example, the interface structure 192 may be linear, as shown in FIG. 17. In another example, the interface structure 192 may be non-linear.

[0131] 18 , in another example of the mating mechanism 104, the interface structure 192 is discontinuous and extends longitudinally along the surface 194 of the fixture 102. In other words, the interface structure 192 may be a plurality of discontinuous interface point structures (e.g., also referred to herein as a plurality of interface structures 192). In one example, the plurality of interface structures 192 may be arranged in a linear fashion, as shown in FIG. 18 . In another example, the plurality of interface structures 192 may be arranged in a non-linear fashion.

[0132] In one example, interface structure 192 is a continuous groove formed in (e.g., originating from) surface 194 of fixture 102. In another example, interface structure 192 is a continuous ridge formed in (e.g., protruding from) surface 194 of fixture 102. In another example, each of the plurality of interface structures 192 includes an opening formed in (e.g., originating from) surface 194. In another example, each of the plurality of interface structures 192 includes a protrusion formed in (e.g., protruding from) surface 194.

[0133] In the illustrated example, the mapping mechanism 104 includes two interface structures 192. In other examples, the mapping mechanism 104 includes any number of interface structures 192. Other structural configurations and / or arrangements of the interface structures 192 are also contemplated.

[0134] 19 , in another example, the interface structure 192 is formed by an edge of the fixture 102. In one example, the edge extends continuously and longitudinally along the fixture 102. In one example, the edge is formed by the intersection of two exposed surfaces 194 (e.g., the top and side) of the fixture 102. In the illustrated example, the interface structure 192 of the mating feature 104 includes or is formed by two edges of the fixture 102. In other examples, the interface structure 192 of the mating feature 104 includes or is formed by any number of edges.

[0135] In another example, interface structure 192 includes a combination of two or more types of structures, such as a groove, a ridge, a series of openings, a series of protrusions, and a lip. Various other configurations of interface structure 192 are also contemplated.

[0136] In examples where the correspondence mechanism 104 includes two or more interface structures 192, the interface structures 192 (e.g., grooves, ridges, openings, protrusions, and edges) are not parallel to one another (e.g., oriented at an angle relative to one another). The non-parallel arrangement of the interface structures 192 can provide non-parallel data points in the sensor data 186 that can be combined during processing to derive XYZ coordinates of multiple data points relative to the frame of reference 216 in two or more dimensions of the fixed coordinate system 112.

[0137] 11-15 , in one example, registration apparatus 100 includes a vehicle 160. Vehicle 160 is configured to support fixture 102 and move fixture 102 relative to work cell 106. In one example, vehicle 160 is configured to move fixture 102, and thus workpiece 170, to work location 258 where sensor 184 scans and detects (e.g., visually identifies) registration mechanism 104 to perform the positioning and registration process described above.

[0138] 1, in the example of the mapping apparatus 100, the vehicle 160 includes or takes the form of an automated guided vehicle 162. With reference to FIGS. 1 and 11, in one example, the vehicle 160 includes or takes the form of a cart 164. The cart 164 is configured to move along a track 166 through the work cell 106.

[0139] In one example, track 166 is positioned so that the Z coordinate of fixture 102, and therefore registration mechanism 104, is fixed and remains constant as cart 164 moves along track 166 to work position 258. In this example, the positioning process performed by sensor 184 only needs to determine the XY coordinates of registration mechanism 104.

[0140] 1 and 11 , in another example, a manufacturing system 168 includes a work cell 106 and an automated machine 128. The automated machine 128 is disposed within the work cell 106 and configured to perform at least one manufacturing process. The manufacturing system 168 also includes a fixture 102. The fixture 102 is configured to support a workpiece 170 and is movable relative to the work cell 106. The manufacturing system 168 further includes an alignment mechanism 104. The alignment mechanism 104 is fixed relative to the fixture 102. For example, the alignment mechanism 104 is disposed on the fixture 102.

[0141] The manufacturing system 168 also includes a sensor 184. The sensor 184 is configured to detect (e.g., visually identify) the associated mechanism 104. The manufacturing system 168 further includes a controller 110 in communication with the sensor 184 and the automated machine 128. The controller 110 is configured to position the fixture 102 relative to the work cell 106 from an associated mechanism location 116 of the associated mechanism 104, as identified by the sensor 184. The controller 110 is also configured to associate the automated machine 128 with the fixture location 118 of the fixture 102.

[0142] 1 and 16 , in an example manufacturing system 168, the controller 110 is configured to determine, from the sensor data 186 generated by the sensor 184, a reference feature position 116 of the reference feature 104 in at least one dimension of the fixed coordinate system 112. The controller 110 is also configured to determine, from the reference feature position 116 of the reference feature 104, a fixture position 118 of the fixture 102 in at least one dimension of the fixed coordinate system 112. The controller 110 is further configured to register a digital model 120 representing the fixture 102 and the reference feature 104 to the reference feature position 116 of the reference feature 104, and to transform a model position 126 of the digital model 120 registered to the reference feature position 116 to the fixture position 118 of the fixture 102.

[0143] 1, 11, and 13, in an example manufacturing system 168, the fixture 102 includes a mandrel 130 configured to support a composite layup, and the automated machine 128 includes an automated fiber placement machine 132 configured to perform at least one composite layup or lamination process.

[0144] 11 and 12, in an example manufacturing system 168, sensor 184 is coupled to automated machine 128, which is configured to move sensor 184 relative to fixture 102 in at least one dimension of fixed coordinate system 112. Referring to Figures 14 and 15, in one example, sensor 184 is configured to move independently of automated machine 128.

[0145] 13 and 17-19, in example manufacturing system 168, mapping mechanism 104 includes at least one interface structure 192 located on a surface 194 of fixture 102. Interface structure 192 is visually detectable (e.g., perceptible and recognizable) by sensor 184.

[0146] 1 and 11-15, in one example, manufacturing system 168 includes vehicle 160. Vehicle 160 is configured to support fixture 102 and move fixture 102 relative to work cell 106.

[0147] 1 and 11 , in one example, manufacturing system 168 also includes a track 166. Track 166 passes through work cell 106. In this example, vehicle 160 includes or takes the form of a cart 164 configured to move along track 166.

[0148] 20 , in one example, manufacturing system 168 includes a second work cell 172. Manufacturing system 168 also includes a second automated machine 174. Second automated machine 174 is disposed within second work cell 172 and is configured to perform at least one manufacturing process on workpiece 170.

[0149] The manufacturing system 168 also includes a second sensor 198. The second sensor 198 is configured to detect (e.g., visually identify) the associated mechanism 104. The controller 110 is in communication with the second sensor 198 and the second automated machine 174. The controller 110 is configured to position the fixture 102 relative to the second work cell 172 from a second associated mechanism position 200 of the associated mechanism 104, as identified by the second sensor 198. The controller 110 is also configured to associate the second automated machine 174 with the second fixture position 180 of the fixture 102. Once associated, the second automated machine 174 performs at least one manufacturing operation on the workpiece 170.

[0150] 1, and particularly, FIGS. 21-23, in another example, the registration apparatus 100 includes a fixture 102. The fixture 102 is movable relative to a work cell 106. The registration apparatus 100 also includes a registration mechanism 104. The registration mechanism 104 is fixed relative to the fixture 102. For example, the registration mechanism 104 may be formed by or otherwise disposed on the fixture 102.

[0151] 21-23, the correspondence feature 104 is coupled to or disposed on at least one side of the fixture 102. In other examples, the correspondence feature 104 is coupled to or disposed on another portion of the fixture 102 (e.g., an opposing side, the front, the back, the top, the bottom, etc.).

[0152] In one example, the registration apparatus 100 includes a plurality of probes 202. The plurality of probes 202 are movable relative to the work cell 106 and the fixture 102. The plurality of probes 202 are configured to engage (e.g., physically contact) the registration mechanism 104. The registration mechanism 104 is suitably positioned relative to the fixture 102 such that at least a portion of the registration mechanism 104 is physically accessible by the plurality of probes 202. Conversely, the plurality of probes 202 are suitably positioned relative to the fixture 102 such that at least a portion of the plurality of probes 202 is physically accessible by the registration mechanism 104. With the plurality of probes 202 engaged with the registration mechanism 104, a plurality of positions of the plurality of probes 202 (also referred to herein as a plurality of probe positions 204) ( FIG. 1 ) represent or correspond to the registration mechanism positions 116 ( FIG. 1 ). In other words, the plurality of probes 202 position the registration mechanism 104 within the reference frame 216.

[0153] 21-23 , in the example of the correlation apparatus 100, the plurality of probes 202 form part of a probe assembly 250 (e.g., the probe assembly 250 includes the plurality of probes 202). The probe assembly 250 includes a drive mechanism 252 coupled to each of the plurality of probes associated with the probe assembly 250. The drive mechanism 252 is configured to move each of the plurality of probes 202 (e.g., collectively referred to as probes 202 and individually referred to as probes 202) relative to the fixture 102 in at least one dimension of the fixed coordinate system 112. For example, the drive mechanism 252 is configured to linearly translate (e.g., extend and retract) each probe 202 in one dimension (e.g., the Y direction) of the fixed coordinate system 112.

[0154] The drive mechanism 252 includes at least one suitable drive motor (not shown), such as an electromechanical motor, a pneumatic motor, or a hydraulic motor, for driving the movement of the probe 202. The probe assembly 250 is also configured to provide position data (e.g., interface data 222) representing multiple positions of the probe 202 (e.g., multiple probe positions 204) in at least one dimension of the fixed coordinate system 112, e.g., relative to the frame of reference 216. For example, the probe assembly 250 also includes at least one encoder (not shown) and / or at least one sensor (not shown) that converts the movement of each probe 202 into an electrical signal representing the probe position 204 of the corresponding probe 202. The probe assembly 250 also includes other suitable electronic, mechanical, pneumatic, and hydraulic components (not shown). The drive mechanism 252 operates under computer control, such as by the controller 110.

[0155] 21 and 22, the registration apparatus 100 includes two probe assemblies 250, e.g., facing each other, such that the probes 202 associated with each of the probe assemblies 250 engage corresponding registration features 104, e.g., located on opposite sides of the fixture 102. In another example, the registration apparatus 100 includes one probe assembly 250, such that the probes 202 associated with the probe assembly 250 engage corresponding registration features 104 located on the fixture 102.

[0156] 1 and 21-23, the registration apparatus 100 also includes a controller 110. The controller 110 is in communication with the plurality of probes 202. The controller 110 is configured to position the fixture 102 relative to the work cell 106 from a plurality of probe positions 204 of the plurality of probes 202 with the plurality of probes 202 engaged with the registration mechanism 104.

[0157] In the example of the registration apparatus 100, the controller 110 is configured to determine a plurality of probe positions 204 of the plurality of probes 202 in at least one dimension of the fixed coordinate system 112, e.g., relative to the frame of reference 216. The controller 110 is also configured to determine a registration feature position 116 of the registration feature 104 in at least one dimension of the fixed coordinate system 112, e.g., relative to the frame of reference 216, from the plurality of probe positions 204 of the plurality of probes 202. The controller 110 is further configured to determine a fixture position 118 of the fixture 102 in at least one dimension of the fixed coordinate system 112, e.g., relative to the frame of reference 216, from the registration feature position 116 of the registration feature 104.

[0158] In one example, the controller 110 is configured to register a digital model 120 ( FIG. 1 ) representing the fixture 102 and the reference feature 104 to a reference feature location 116 of the reference feature 104. The controller 110 is also configured to convert a model location 126 of the digital model 120 registered to the reference feature location 116 to a fixture location 118 of the fixture 102.

[0159] FIG. 24 schematically illustrates an example of inputs 234 provided to and outputs 236 generated by the controller 110 during the positioning and registration process. In one example, probe position data 254 is provided to the controller 110 by the probe assembly 250. The probe position data 254 is an example of interface data 222 (FIG. 1). In one example, the probe position data 254 is generated by an encoder, a sensor, other relative position information device, or a combination thereof, and represents the actual physical positions (probe positions 204) of the multiple probes 202 (FIG. 13). The controller 110 processes the probe position data 254 and determines the probe positions 204 based on the probe position data 254. The controller 110 then processes the probe positions 204 and determines the registration mechanism positions 116 based on the probe positions 204.

[0160] 21-23 , in one example, when the probe 202 is engaged with the matching mechanism 104, there are multiple contact points between the probe 202 and the matching mechanism 104. Each of these contact points has X, Y, and Z coordinates that are common to both the corresponding probe 202 and the matching mechanism 104. Probe position data 254 ( FIG. 24 ) represents the X, Y, and Z coordinates of the contact points of the probe 202 (e.g., the X, Y, and Z coordinates of each probe 202 contact point), and the probe position 204 is described by the X, Y, and Z coordinates of the contact points of the probe 202. The controller 110 converts the X, Y, and Z coordinates of the contact points of the probe 202 into the X, Y, and Z coordinates of the corresponding contact points of the matching mechanism 104. The controller 110 then determines the matching mechanism position 116, which is described by the X, Y, and Z coordinates of the contact points of the matching mechanism 104.

[0161] In one example, the probe assembly 250 includes at least two probes 202 corresponding to at least two points of contact between the probes 202 and the registration feature 104, thereby providing at least two X, Y, and Z coordinates describing the registration feature position 116 of the registration feature 104. In another example, the probe assembly 250 includes at least three probes 202 corresponding to at least three points of contact between the probes 202 and the registration feature 104, thereby providing at least three X, Y, and Z coordinates describing the registration feature position 116 of the registration feature 104. In another example, the combination of probes 202 from two or more probe assemblies 250 corresponds to at least three points of contact between the probes 202 and the registration feature 104, thereby providing at least three X, Y, and Z coordinates describing the registration feature position 116 of the registration feature 104.

[0162] In one example, the multiple contact points are provided by probes 202 of one probe assembly 250 engaging with mating features 104 located on the fixture 102. In another example, some of the contact points are provided by probes 202 associated with a first probe assembly 250 engaging with a first portion of a mating feature 104 (or first mating feature 104) located on a first side (or first surface) of the fixture 102, and some of the contact points are provided by probes 202 associated with a second probe assembly 250 engaging a second portion of a mating feature 104 (or second mating feature 104) located on a second side (or second surface) of the fixture 102.

[0163] It should be noted that increasing the number of contact points between the probes 202 and the registration mechanism 104 (e.g., by increasing the number of probes 202 engaging with the registration mechanism 104) provides a greater number of XYZ coordinate data points for processing, thereby increasing the accuracy of the registration mechanism position 116 and fixture position 118 during alignment of the data points in the registration process.

[0164] In the illustrated example, the probes 202 (e.g., of opposing probe assemblies 250) are positioned to engage portions of the mating feature 104 (or different mating features 104) located on opposite sides (e.g., sides) of the fixture 102. In other examples (not shown), the probes 202 (e.g., of additional or alternative probe assemblies 250) are positioned to engage portions of the mating feature 104 (or different mating features 104) located on another portion or surface (e.g., top, bottom, front, back, etc.) of the fixture 102.

[0165] 27 , in one example, the probe 202 includes a contact indicator 148 and the mapping mechanism 104 includes an interface indicator 146. When the probe 202 is engaged with the mapping mechanism 104, there is a contact point between the contact indicator 148 and the interface indicator 146. This contact point has XYZ coordinates that are common to both the contact indicator 148 and the interface indicator 146. The probe position data 254 represents the XYZ coordinates of the contact point of the contact indicator 148 of the probe 202, and the probe position 204 of the probe 202 is described by the XYZ coordinates of the contact point of the contact indicator 148 of the probe 202.

[0166] The controller 110 converts the XYZ coordinates of the contact point on the contact indicator 148 into the XYZ coordinates of the corresponding contact point on the interface indicator 146. The controller 110 determines the mapping feature position 116 described by the XYZ coordinates of the contact point on the interface indicator 146.

[0167] Generally, the plurality of probes 202 includes or forms a plurality of contact indicators 148, and the correspondence mechanism 104 includes or forms a plurality of interface indicators 146, thereby providing a plurality of contact points. Thus, the probe position data 254 (FIG. 24) represents the XYZ coordinates of the plurality of contact points of the contact indicators 148 of the probes 202. The plurality of probe positions 204 are described by the XYZ coordinates of the contact points of the contact indicators 148 of the plurality of probes 202. The correspondence mechanism position 116 is described by the XYZ coordinates of the corresponding plurality of contact points of the interface indicators 146.

[0168] It should be noted that increasing the number of contact indicators 148 and interface indicators 146 increases the number of contact points between the probe 202 and the registration mechanism 104, resulting in a greater number of XYZ coordinate data points for processing, thereby increasing the accuracy of the registration mechanism position 116 and fixture position 118 during alignment of the data points in the registration process. In one example, the probe assembly 250 (e.g., multiple probe assemblies 202) includes at least three contact indicators 148, and the registration mechanism 104 includes at least three interface indicators 146.

[0169] 24 , the controller 110 is configured to register the digital model 120 representing the fixture 102 and the reference feature 104 to the reference feature location 116 to determine the model location 126. In one example, the controller 110 is configured to register and align the digital model 120 with XYZ coordinates describing the reference feature location 116 within the reference frame 216. The digital model 120 includes data points representing contact points of the reference feature 104. For example, the digital model 120 includes data points representing the interface indicator 146 of the reference feature 104. In one example, the controller 110 performs a best-fit process (e.g., a best-fit algorithm is implemented) to align the data points representing the contact points of the reference feature 104, such as the data points representing the interface indicator 146, with the data points representing the XYZ coordinates describing the reference feature location 116. In one example, the best-fit process includes a rigid point cloud transformation process.

[0170] With the digital model 120 registered and aligned with the associated mechanism position 116, the controller 110 is configured to transform the model position 126 into a fixture position 118 of the fixture 102 relative to the frame of reference 216. For example, the fixture position 118 is assumed to be the same as the model position 126 within a tolerance. Thus, the fixture position 118 represents the most recent (e.g., current, real-time) position of the fixture 102, and thus the workpiece 170, relative to the work cell 106 and automated machine 128.

[0171] When the fixture location 118 is known, the automated machine 128 is mapped or "zeroed" to the fixture location 118 and performs a manufacturing process on the workpiece 170 according to a predetermined toolpath. Based on the fixture location 118, the automated machine 128 is mapped to the fixture 102, and consequently, the automated machine 128 is mapped to the workpiece 170. The geometry of the workpiece 170 and the known position of the workpiece 170 relative to the fixture 102 are incorporated into and accounted for by the programmed toolpath of the automated machine 128.

[0172] 1 and 21 , in one example, the mapping apparatus 100 includes an automated machine 128. The automated machine 128 is located within the work cell 106. The automated machine 128 is in communication with the controller 110. The controller 110 is configured to map the automated machine 128 to a fixture position 118 of the fixture 102.

[0173] 22 and 23, in one example, the automated machine 128 includes a gantry 134. In this example, the fixture 102, and thus the workpiece 170, is moved to a work position 258 within the work cell 106, and the gantry 134 and / or a robotic arm 226 coupled to the gantry 134 moves relative to the fixture 102 such that the end effector 228 follows a predetermined toolpath.

[0174] In another example (not shown), the robot arm 226 is a free-standing robot with a fixed base within the work cell 106. In this example, the fixture 102, and therefore the workpiece 170, is moved to a work position 258 within the work cell 106, and the robot arm 226 moves relative to the fixture 102 such that the end effector 228 follows a predetermined toolpath.

[0175] Although the illustrated example of the alignment apparatus 100 shows only one automated machine 128 (e.g., one robotic arm 226 with one end effector 228) for performing manufacturing processes on the workpieces 170 in the work cell 106, in other examples, the alignment apparatus 100 may have any number of additional automated machines 128 (e.g., additional robotic arms 226 and / or additional end effectors 228).

[0176] 1 and 22, in one example, the manufacturing process includes a pre-cured composite assembly process, such as a composite layup process and / or a composite lamination process. In this example, the workpiece 170 includes a composite layup (e.g., a composite layup). The fixture 102 includes or takes the form of a mandrel 130. The mandrel 130 is configured to support the composite layup. The automated machine 128 includes or takes the form of an automated fiber placement machine 132.

[0177] In one example, the fixture 102 is moved to the work position 258, and the proximate position of the fixture 102 and the workpiece 170 (e.g., fixture position 118) is determined using the plurality of probes 202 and the registration mechanism 104, as described above. Based on the fixture position 118 (e.g., the position of the fixture 102 and the position of the workpiece 170 relative to the fixture 102), the automated fiber placement machine 132 lays and / or compacts at least a portion of at least one layer of the stack of composite laminations.

[0178] In one or more other examples (not explicitly shown), the manufacturing process includes another assembly process or machining. In such examples, workpiece 170 may be a post-cure composite workpiece, a metal workpiece, a plastic workpiece, or other non-composite workpiece. Fixture 102 includes a suitable holding mechanism 260 ( FIG. 1 ) configured to secure workpiece 170 during transfer to work cell 106 and during the manufacturing process. Automated machine 128 may include or take the form of any suitable machine tool.

[0179] In one example, the registration device 100 includes an independent movement mechanism (not shown) configured to move the fixture 102 to the work position 258 .

[0180] 25 and 26 schematically illustrate an example of the mating mechanism 104. FIG. 27 schematically illustrates an example of a probe 202 and mating mechanism 104. Generally, the mating mechanism 104 includes at least one interface indicator 146. In one example, the interface indicator 146 is disposed (e.g., located or formed) on the surface 194 of the fixture 102. Each of the plurality of probes 202 includes a contact indicator 148 ( FIG. 27 ). The contact indicator 148 is movable relative to the at least one interface indicator 146. The contact indicator 148 is configured to engage the interface indicator 146 to enable the probe 202 to position the mating mechanism 104.

[0181] 27 , in one example, each probe 202 includes a probe head 208. The probe 202 is configured to move relative to the fixture 102 in at least one dimension of the fixed coordinate system 112 to engage the probe head 208 with the mapping mechanism 104. In one example, each probe 202 includes a probe shaft 256. The probe head 208 is coupled to an end of the probe shaft 256. The drive mechanism 252 is configured to extend or retract the probe shaft 256 to move the probe head 208.

[0182] In one example, interface indicator 146 includes or is formed by at least one interface structure 206 disposed on surface 194 of fixture 102. For example, interface indicator 146 is formed by a portion of interface structure 206, such as a portion of the surface of interface structure 206. In one example, contact indicator 148 includes or is formed by probe head 208. In this example, probe head 208 is a contact structure of contact indicator 148. For example, contact indicator 148 is formed by a portion of probe head 208, such as a portion of the surface of probe head 208.

[0183] In one example, the contact indicator 148 contacts the interface indicator 146 as the probe head 208 is configured to engage with the interface structure 206. The contact indicator 148 and the interface indicator 146 are configured to contact and mate with each other when the probe 202 (e.g., the probe head 208) is properly engaged with the mating feature 104 (e.g., the interface structure 206).

[0184] 25, in one example of the mating mechanism 104, the interface structure 206 is continuous and extends longitudinally along the surface 194 (e.g., side) of the fixture 102. In other words, the interface structure 206 may be a continuous interface structure. In one example, the interface structure 206 may be linear, as shown in FIG. 25. In another example, the interface structure 206 may be non-linear.

[0185] 26, in another example of the mating mechanism 104, the interface structure 206 is discontinuous and extends longitudinally along the surface 194 of the fixture 102. In other words, the interface structure 206 may be a plurality of discontinuous interface point structures (e.g., also referred to herein as a plurality of interface structures 206). In one example, the plurality of interface structures 206 may be arranged in a non-linear fashion. In another example, the plurality of interface structures 206 may be arranged in a non-linear fashion as shown in FIG. 26.

[0186] In one example, the probe head 208 and the interface structure 206 have complementary geometric shapes and dimensions such that corresponding surfaces of the probe head 208 (e.g., forming the contact indicator 148) and the interface structure 206 (e.g., forming the interface indicator 146) are in contact when the probe 202 is properly engaged with the mating mechanism 104. The probe head 208 and the interface structure 206 each include or take the form of any one of a variety of structural configurations.

[0187] In one example, interface structure 206 is a continuous groove formed in (e.g., originating from) surface 194 of fixture 102. In this example, probe head 208 is configured to be inserted into a portion of interface structure 206. In another example, interface structure 206 is a continuous ridge formed in (e.g., protruding from) surface 194 of fixture 102. In this example, probe head 208 is configured to receive a portion of interface structure 206. In another example, each of the plurality of interface structures 206 includes an opening formed in (e.g., originating from) surface 194. In this example, probe head 208 is configured to be inserted into interface structure 206. In another example, each of the plurality of interface structures 206 includes a protrusion formed in (e.g., protruding from) surface 194. In this example, probe head 208 is configured to receive interface structure 206.

[0188] Other structural configurations and / or arrangements of the contact indicator 148 (eg, probe head 208) and interface indicator 146 (eg, interface structure 206) are also contemplated.

[0189] In another example of the mating mechanism 104 , the interface structure 206 includes or takes the form of at least one surface 194 (eg, an outer surface) of the fixture 102 . In other words, the surface 194 of the fixture 102 is configured such that each of the plurality of probes 202, which is the interface structure 206 of the interface indicator 146, moves the probe head 208 into contact with the surface 194 of the fixture 102. For example, the drive mechanism 252 extends the probe shaft 256 to move the probe head 208 into contact with the surface 194, thereby positioning the contact indicator 148 formed by a portion of the surface of the probe head 208 into contact with the interface indicator 146 formed by a portion of the surface 194 of the fixture 102.

[0190] 27 , in an example of the registration apparatus 100, the probe assembly 250 includes a displacement sensor 210. The displacement sensor 210 is in communication with each of the plurality of probes 202. The displacement sensor 210 is configured to measure the displacement of the plurality of probes 202 (e.g., each of the probes 202) in at least one dimension of the fixed coordinate system 112 as the plurality of probes 202 moves into contact with the registration mechanism 104. In one example, the displacement sensor 210 generates displacement data that represents the displacement or movement of the probe 202 and corresponds to the probe position 204. This displacement data is an example of the probe position data 254 ( FIG. 24 ) that is provided to the controller 110.

[0191] 21-23, in one example, registration apparatus 100 includes a vehicle 160. Vehicle 160 is configured to support fixture 102 and move fixture 102 relative to work cell 106. In one example, vehicle 160 is configured to move fixture 102, and thus workpiece 170, to a work position 258 where multiple probes 202 extend to engage registration mechanism 104 to perform the positioning and registration steps described above.

[0192] 1, in the example of the mapping apparatus 100, the vehicle 160 includes or takes the form of an automated guided vehicle 162. With reference to FIGS. 1 and 22, in the example of the mapping apparatus 100, the vehicle 160 includes or takes the form of a cart 164. The cart 164 is configured to move along a track 166 through the work cell 106.

[0193] In one example, the track 166 is positioned so that the Z coordinate of the fixture 102, and therefore the registration mechanism 104, is fixed and remains constant as the cart 164 moves along the track 166 to the work position 258. In this example, the positioning process performed by the multiple probes 202 need only determine the XY coordinates of the registration mechanism 104.

[0194] 1 and 21 , in another example, a manufacturing system 168 includes a work cell 106 and an automated machine 128. The automated machine 128 is disposed within the work cell 106 and configured to perform at least one manufacturing process. The manufacturing system 168 also includes a fixture 102. The fixture 102 is configured to support a workpiece 170 and is movable relative to the work cell 106. The manufacturing system 168 further includes an association mechanism 104. The association mechanism 104 is fixed relative to the fixture 102. For example, the association mechanism 104 is disposed on the fixture 102.

[0195] The manufacturing system 168 also includes a plurality of probes 202. The plurality of probes 202 are movable relative to the work cell 106 and the fixture 102. The plurality of probes 202 are configured to engage the registration mechanism 104. The manufacturing system 168 further includes a controller 110 in communication with the plurality of probes 202 and the automated machine 128. The controller 110 is configured to position the fixture 102 relative to the work cell 106 from a plurality of probe positions 204 of the plurality of probes 202 engaged with the registration mechanism 104. The controller 110 is also configured to register the automated machine 128 with the fixture position 118 of the fixture 102.

[0196] 1 and 24 , in example manufacturing system 168, controller 110 is configured to determine a plurality of probe positions 204 of a plurality of probes 202 in at least one dimension of fixed coordinate system 112, e.g., relative to frame of reference 216. Controller 110 is also configured to determine, from the plurality of probe positions 204 of the plurality of probes 202, a corresponding feature position 116 of a corresponding feature 104 in at least one dimension of fixed coordinate system 112, e.g., relative to frame of reference 216. Controller 110 is further configured to determine, from the corresponding feature position 116 of a corresponding feature 104, a fixture position 118 of a fixture 102 in at least one dimension of fixed coordinate system 112, e.g., relative to frame of reference 216. The controller 110 is also configured to register a digital model 120 representing the fixture 102 and the associated feature 104 to the associated feature position 116 of the associated feature 104, and to convert a model position 126 of the digital model 120 registered to the associated feature position 116 to a fixture position 118 of the fixture 102.

[0197] 1 and 21, in an example manufacturing system 168, the fixture 102 includes or takes the form of a mandrel 130 configured to support a composite layup, and the automated machine 128 includes or takes the form of an automated fiber placement machine 132.

[0198] 21 and 22 , in an example manufacturing system 168, a plurality of probes 202 are configured to engage with an association mechanism 104 while the fixture 102 is within the work envelope 140 of the work cell 106. In the example manufacturing system 168, the association mechanism 104 includes or takes the form of at least one surface 194 of the fixture 102. Each of the plurality of probes 202 moves along at least one dimension of the fixed coordinate system 112 into contact with the at least one surface 194.

[0199] 23 and 25-27, in an example manufacturing system 168, the mapping mechanism 104 includes at least one interface indicator 146 disposed on the surface 194 of the fixture 102. Each of the plurality of probes 202 is movable relative to the at least one interface indicator 146 and includes a contact indicator 148 configured to engage the at least one interface indicator 146. In one example, the interface indicator 146 includes an interface structure 206, and the contact indicator 148 includes a probe head 208 of a corresponding one of the plurality of probes 202. The probe head 208 is configured to engage the interface structure 206 such that the contact indicator 148 contacts the interface indicator 146.

[0200] 1 and 21-23, in one example, manufacturing system 168 includes vehicle 160. Vehicle 160 is configured to support fixture 102 and move fixture 102 relative to work cell 106.

[0201] 1 and 21 , in one example, manufacturing system 168 also includes a track 166. Track 166 passes through work cell 106. In this example, vehicle 160 includes or takes the form of a cart 164 configured to move along track 166.

[0202] 28, in one example, manufacturing system 168 includes a second work cell 172 and a second automated machine 174. Second automated machine 174 is disposed in work cell 106 and configured to perform at least one manufacturing process.

[0203] The manufacturing system 168 also includes a second plurality of probes 212. The second plurality of probes 212 are movable relative to the second work cell 172 and the fixture 102. The second plurality of probes 212 are configured to engage the mapping mechanism 104. A controller 110 is in communication with the second plurality of probes 212 and the second automated machine 174. The controller 110 is configured to position the fixture 102 relative to the second work cell 172 from the second plurality of probe positions 214 of the second plurality of probes 212 engaged with the mapping mechanism 104. The controller 110 is further configured to map the second automated machine 174 to the second fixture position 180 of the fixture 102. Once mapped, the second automated machine 174 performs at least one manufacturing operation on the workpiece 170.

[0204] 10, 20, and 28, in an example manufacturing system 168, a track 166 extends from the work cell 106 to and passes through the second work cell 172. In other words, the track 166 connects the work cell 106 to the second work cell 172. As shown in FIGS. 10, 20, and 28, in one example, the work cell 106 and the second work cell 172 are arranged in a continuously connected row. In these examples, the manufacturing system 168 is a continuous flow manufacturing system in which at least a portion of one or more manufacturing processes are performed in each work cell. Although only two work cells (e.g., the work cell 106 and two work cells 172) are shown as examples in FIGS. 10, 20, and 28, in other examples, the manufacturing system 168 may include any number of work cells.

[0205] 10, 20, and 28, the entire fixture 102 and the entire workpiece 170 are disposed in a corresponding one of the work cell 106 and the second work cell 172 as the fixture 102 and the workpiece 170 move continuously along the manufacturing system 168. However, in other examples, the fixture 102 and the workpiece 170 extend between two or more work cells of the manufacturing system 168. For example, a first portion (or first section) of the fixture 102 and a first portion (or first section) of the workpiece 170 are disposed in the work cell 106, and a second portion (or second section) of the fixture 102 and a second portion (or second section) of the workpiece 170 are disposed in the second work cell 172. In this example of manufacturing system 168, work cell 106 and second work cell 172 are interdependent such that the manufacturing processes performed in second work cell 172 build on or are in addition to the manufacturing processes performed in work cell 106. This configuration is particularly advantageous in instances where fixture 102 and workpiece 170 are large, elongated structures. For example, workpiece 170 may be an aircraft spar, airfoil, or fuselage section, and fixture 102 is a fixture configured to support and securely hold large workpiece 170.

[0206] In another example (not shown) of manufacturing system 168, work cell 106 and second work cell 172 are located separately and are independent of each other. In this example, vehicle 160 (e.g., automated guided vehicle 162) is configured to travel along a predetermined travel path to move fixture 102 and workpiece 170 between the different work cells.

[0207] In the example shown, the mounting fixture 102 is a rigid body, and the reference mechanism 104 is coupled to the mounting fixture 102. However, in other examples, the mounting fixture 102 and the vehicle 160 form a rigid body. For example, the mounting fixture 102 and the vehicle 160 may be integrated into a single member. In such examples, the position of the reference mechanism 104 is also fixed relative to the vehicle 160. For example, the reference mechanism 104 may be coupled to, located on, or otherwise associated with the vehicle 160 rather than the mounting fixture 102.

[0208] As described herein, the positioning and registration process advantageously allows the fixture 102 and workpiece 170 to be moved to an approximate location within the work cell 106 relative to the automated machine 128. The most recent location of the fixture 102 (e.g., fixture location 118), as determined by, for example, the gripper 108, sensor 184, or probe 202 described above, becomes the work location 258, and the automated machine 128 registers itself from the fixture location 118. This process improves the cycle time of the manufacturing process by eliminating the need for incremental registration of the automated machine 128 relative to the workpiece 170 and the need to set up the workpiece 170 in a specific, predetermined location using non-moving fixtures.

[0209] As described herein, the positioning and registration process also advantageously allows subsequent fixtures 102 and workpieces 170 to be located at suitably different work locations within the work cell 106 and relative to the automated machine 128. In other words, the work location 258 of the fixture 102 and workpiece 170 at which the manufacturing process occurs need not be the same, fixed, and repeatable location for subsequent workpieces 170.

[0210] Although not explicitly shown, in one or more examples of the registration apparatus 100 and / or manufacturing system 168, the interface device 220 includes a combination (e.g., two or more) of grippers 108, sensors 184, and / or probes 202. The combination of grippers 108, sensors 184, and / or probes 202 is used to interface with a corresponding registration mechanism 104 and position and register the fixture 102 based on the position of the registration mechanism 104.

[0211] FIG. 29 is a flow diagram of an example manufacturing method 1000. With general reference to FIGS. 1-10 and, in particular, FIG. 29, manufacturing method 1000 includes securing workpiece 170 to fixture 102 (block 1002). With workpiece 170 secured to fixture 102, the position of workpiece 170 (workpiece position 262) is fixed and known relative to fixture 102. Additionally, the geometry of workpiece 170 (workpiece geometry 268) is known. Positioning fixture 102 relative to work cell 106 (e.g., relative to frame of reference 216) according to method 1000, in turn, positions workpiece 170 relative to work cell 106 (e.g., relative to frame of reference 216).

[0212] The method 1000 includes moving the fixture 102 relative to the work cell 106 (block 1004). The method 1000 also includes engaging the registration mechanism 104 with the gripper 108 (block 1006). The position of the registration mechanism 104 (registration mechanism position 116) is fixed and known relative to the fixture 102. In one example, the registration mechanism 104 is coupled to the fixture 102. The method 1000 further includes positioning the fixture 102 relative to the work cell 106 from the position of the gripper 108 (gripper position 114) with the gripper 108 engaged with the registration mechanism 104 (block 1010).

[0213] Method 1000 includes mapping (block 1016) the automated machine 128 to the position of the fixture 102 (fixture location 118). According to method 1000, mapping the automated machine 128 to the position of the fixture 102 (fixture location 118) in turn maps the automated machine 128 to the position of the workpiece 170 (workpiece location 262). Method 1000 further includes (block 1018) using the automated machine 128 to perform at least one manufacturing process on the workpiece 170. Once the automated machine 128 is mapped to the position of the fixture 102 (fixture location 118), the geometry of the workpiece 170 (workpiece geometry 268) and the position of the workpiece 170 relative to the fixture 102 (workpiece location 262) are incorporated into and accounted for by the programmed toolpath of the automated machine 128 during the execution of the manufacturing process.

[0214] In one example, method 1000 includes determining (block 1008) a position of gripper 108 relative to work cell 106, e.g., relative to frame of reference 216, in at least one dimension of fixed coordinate system 112 (gripper position 114). Method 1000 also includes determining (block 1012) a position of reference mechanism 104 relative to work cell 106, e.g., relative to frame of reference 216, in at least one dimension of fixed coordinate system 112 from the position of gripper 108 (gripper position 114). Method 1000 further includes determining (block 1014) a position of fixture 102 relative to work cell 106, e.g., relative to frame of reference 216, in at least one dimension of fixed coordinate system 112 (fixture position 118) from the position of reference mechanism 104 (reference mechanism position 116).

[0215] In one example, the method 1000 includes registering the digital model 120 representing the fixture 102 and the reference feature 104 to the position of the reference feature 104 (the reference feature position 116). The method 1000 also includes converting the position of the digital model 120 (the model position 126) registered to the position of the reference feature 104 (the reference feature position 116) to the position of the fixture 102 (the fixture position 118). In other words, when the digital model 120 is registered to the position of the reference feature 104 (the reference feature position 116), the position of the fixture 102 (the fixture position 118) is assumed to be the same (within tolerance) as the position of the digital model 120 (the model position 126).

[0216] In one example, the method 1000 includes a step of moving the fixture 102 to a work position 258 (e.g., within the work envelope 140 of the work cell 106) using the gripper 108 while (e.g., substantially simultaneously) determining a position of the gripper 108 (gripper position 114) (block 1008) and determining a position of the association mechanism 104 (association mechanism position 116) (block 1008).

[0217] In one example, method 1000 includes, for example, when performing engaging the registration mechanism 104 with the gripper 108 (block 1004), engaging the interface indicator 146 of the registration mechanism 104 with the contact indicator 148 of the gripper 108. Method 1000 also includes generating gripper position data 238 representing the XYZ coordinates of the point of contact between the contact indicator 148 and the interface indicator 146.

[0218] In one example, the method 1000 includes gripping the plate 150 of the association mechanism 104 with the jaw assembly 144 of the gripper 108. The method 1000 also includes engaging an interface indicator 146 coupled to the plate 150 with a contact indicator coupled to the jaw assembly 144.

[0219] FIG. 30 is a flow diagram of an example manufacturing method 2000. With general reference to FIGS. 1 and 11-20, and particularly to FIG. 30, in one example, method 3000 includes securing workpiece 170 to fixture 102 (block 2002). With workpiece 170 secured to fixture 102, the position of workpiece 170 (workpiece position 262) is fixed and known relative to fixture 102. Additionally, the geometry of workpiece 170 (workpiece geometry 268) is known. Positioning fixture 102 relative to work cell 106 (e.g., relative to frame of reference 216) according to method 1000, in turn, positions workpiece 170 relative to work cell 106 (e.g., relative to frame of reference 216).

[0220] Method 2000 includes moving fixture 102 relative to work cell 106 (block 2004). Method 2000 also includes detecting (e.g., visually identifying) reference feature 104 with sensor 184 (block 2006). The position of reference feature 104 (reference feature position 116) is fixed and known relative to fixture 102. In one example, reference feature 104 is disposed on fixture 102. Method 2000 further includes positioning fixture 102 relative to work cell 106 from the position of reference feature 104 (reference feature position 116) detected by sensor 184 (block 2008).

[0221] Method 2000 also includes mapping (block 2014) the automated machine 128 to the position of the fixture 102 (fixture location 118). According to method 2000, mapping the automated machine 128 to the position of the fixture 102 (fixture location 118) in turn maps the automated machine 128 to the position of the workpiece 170 (workpiece location 262). Method 2000 further includes using the automated machine 128 to perform at least one manufacturing operation on the workpiece 170 (block 2016). Once the automated machine 128 is mapped to the position of the fixture 102 (fixture location 118), the geometry of the workpiece 170 (workpiece geometry 268) and the position of the workpiece 170 relative to the fixture 102 (workpiece location 262) are incorporated into and accounted for by the programmed toolpath of the automated machine 128 during the execution of the manufacturing operation.

[0222] In one example, method 2000 includes determining (block 2010) a position of the reference mechanism 104 (reference mechanism position 116) relative to the work cell 106, e.g., relative to the frame of reference 216, in at least one dimension of the fixed coordinate system 112 from sensor data 186 generated by sensor 184. Method 2000 also includes determining (block 2012) a position of the fixture 102 (fixture position 118) relative to the work cell 106, e.g., relative to the frame of reference 216, in at least one dimension of the fixed coordinate system 112 from the position of the reference mechanism 104 (reference mechanism position 116).

[0223] In one example, the method 2000 includes registering the digital model 120 representing the fixture 102 and the reference feature 104 to the position of the reference feature 104 (the reference feature position 116). The method 2000 also includes converting the position of the digital model 120 (the model position 126) registered to the position of the reference feature 104 (the reference feature position 116) to the position of the fixture 102 (the fixture position 118). In other words, when the digital model 120 is registered to the position of the reference feature 104 (the reference feature position 116), the position of the fixture 102 (the fixture position 118) is assumed to be the same (within tolerance) as the position of the digital model 120 (the model position 126).

[0224] In one example, method 2000 includes using sensor 184 to detect (e.g., visually identify) at least one interface structure 192 of mapping mechanism 104 located on surface 194 of fixture 102. Method 2000 also includes generating sensor data 186 representing XYZ coordinates of interface structure 192.

[0225] FIG. 31 is a flow diagram of an example manufacturing method 3000. With general reference to FIGS. 1 and 21-28, and particularly to FIG. 30, manufacturing method 3000 includes securing workpiece 170 to fixture 102 (block 3002). With workpiece 170 secured to fixture 102, the position of workpiece 170 (workpiece position 262) is fixed and known relative to fixture 102. In addition, the geometry of workpiece 170 (workpiece geometry 268) is known. Positioning fixture 102 relative to work cell 106 (e.g., relative to frame of reference 216) according to method 1000, in turn, positions workpiece 170 relative to work cell 106 (e.g., relative to frame of reference 216).

[0226] The method 3000 includes moving the fixture 102 relative to the work cell 106 (block 3004). The method 3000 also includes engaging the registration mechanism 104 with the plurality of probes 202 (block 3006). The position of the registration mechanism 104 (registration mechanism position 116) is fixed and known relative to the fixture 102. In one example, the registration mechanism 104 is coupled to the fixture 102. The method 3000 further includes positioning the fixture 102 relative to the work cell 106 from the position of the plurality of probes 202 (plurality of probe positions 204) with the plurality of probes 202 engaged with the registration mechanism 104 (block 3010).

[0227] Method 3000 further includes mapping (block 3016) the automated machine 128 to the position of the fixture 102 (fixture location 118). According to method 3000, mapping the automated machine 128 to the position of the fixture 102 (fixture location 118) in turn maps the automated machine 128 to the position of the workpiece 170 (workpiece location 262). Method 3000 further includes using the automated machine 128 to perform at least one manufacturing operation on the workpiece 170 (block 3018). Once the automated machine 128 is mapped to the position of the fixture 102 (fixture location 118), the geometry of the workpiece 170 (workpiece geometry 268) and the position of the workpiece 170 relative to the fixture 102 (workpiece location 262) are incorporated into and accounted for by the programmed toolpath of the automated machine 128 during the execution of the manufacturing operation.

[0228] In one example, the method 3000 includes determining (block 3008) positions of the plurality of probes 202 (plurality of probe positions 204) relative to the work cell 106, e.g., relative to the frame of reference 216, in at least one dimension of the fixed coordinate system 112. The method 3000 also includes determining (block 3012) a position of the registration feature 104 (registration feature position 116) relative to the work cell 106, e.g., relative to the frame of reference 216, in at least one dimension of the fixed coordinate system 112 from the positions of the plurality of probes 202 (plurality of probe positions 204). The method 3000 further includes determining (block 3014) a position of the fixture 102 (fixture position 118) relative to the work cell 106, e.g., relative to the frame of reference 216, in at least one dimension of the fixed coordinate system 112 from the position of the registration feature 104 (registration feature position 116).

[0229] In one example, the method 3000 includes registering the digital model 120 representing the fixture 102 and the reference feature 104 to the position of the reference feature 104 (the reference feature position 116). The method 3000 includes converting the position of the digital model 120 (the model position 126) registered to the position of the reference feature 104 (the reference feature position 116) to the position of the fixture 102 (the fixture position 118). In other words, when the digital model 120 is registered to the position of the reference feature 104 (the reference feature position 116), the position of the fixture 102 (the fixture position 118) is assumed to be the same (within tolerance) as the position of the digital model 120 (the model position 126).

[0230] In one example, the method 3000 includes moving the fixture 102 to the work location 258 (e.g., within the work envelope 140 of the work cell 106). The method 3000 also includes moving the plurality of probes 202 along at least one dimension of the fixed coordinate system 112 into contact with the mapping mechanism 104.

[0231] In one example, the method 3000 includes, for example, when performing the step of engaging the mapping mechanism 104 with the plurality of probes 202 (block 3006), engaging the interface indicator 146 of the mapping mechanism 104 with the contact indicator 148 of each probe 202. The method 3000 also includes generating probe position data 254 representing the XYZ coordinates of the contact point between the contact indicator 148 and the interface indicator 146.

[0232] In one example, the method 3000 includes engaging an interface structure 206 of the mating mechanism 104 with a probe head 208 of the probe 202. The method 1000 also includes engaging an interface indicator 146 formed by the interface structure 206 with a contact indicator 148 formed by the probe head 208.

[0233] 32 schematically illustrates an example of the controller 110, and more specifically, the computing device 224 of the controller 110. The controller 110 may include any suitable programmable controller configured to control one or more manufacturing processes and perform one or more computing or data processing operations. The steps performed by the various examples of the disclosed mapping apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000, and / or portions thereof are performed under computer control provided by the controller 110. The controller 110 may be any number of programmable controllers and / or include any number of computing devices 224.

[0234] Computing device 224 is an example of a data processing system that may be used to perform one or more of the functions provided by the disclosed mapping apparatus 100 and manufacturing system 168, or to implement one or more of the operational steps of the disclosed methods 1000, 2000, 3000. Computing device 224 includes a communication bus 602 that provides communication between a processor unit 604, a memory 606, a persistent storage device 608, a communication unit 610, an input / output ("I / O") unit 612, and a display 614.

[0235] The communication bus 602 may include one or more buses, such as a system bus or an input / output bus, and may be implemented using any suitable type of architecture that provides for a transfer of data between different components or devices attached to the bus system.

[0236] Processor unit 604 is any suitably programmed computer processor configured to execute instructions, such as software instructions, loaded into memory 606. Processor unit 604 may be any number of processors, a multi-processor core, a microprocessor, or any other type of processor, depending on the implementation of controller 110.

[0237] Memory 606 and persistent storage 608 are examples of storage device 616. Storage device 616 is any hardware capable of storing information, including, but not limited to, temporary and / or persistent data, program code in functional form, and / or other suitable information. For example, memory 606 may be a random access memory or any other suitable volatile or non-volatile storage device. Memory 606 is also referred to as a non-transitory computer-readable storage medium.

[0238] Persistent storage 608 may take various forms, depending on the implementation. Persistent storage 608 may comprise one or more components or devices. For example, persistent storage 608 may be a hard drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of these.

[0239] Communications unit 610 provides for communication with other data processing systems or devices, such as via wired and / or wireless communication links, and may include one or more devices used to transmit and receive data, such as a network interface card, modem, or network adapter.

[0240] The input / output unit 612 allows for the input and output of data with other devices connected to the controller 110. For example, the input / output unit 612 may provide a connection for input through a keyboard, a mouse, and / or some other suitable input device. Further, the input / output unit 612 may send output to a display 614 for displaying information.

[0241] Instructions for the operating system, applications, and / or programs may be located in storage device 616, which is in communication with processor unit 604 via communication bus 602. In one example, the computer-implemented instructions are in a functional form on persistent storage device 608. The instructions are loaded into memory 606 for execution by processor unit 604. One or more of the processes and / or steps described herein are performed by processor unit 604 using the computer-implemented instructions.

[0242] The computer-implemented instructions may be referred to as program code, computer usable program code, or computer readable program code that is readable and executable by at least one processor in processor unit 604. The program code may be embodied on different physical or computer-readable storage media, such as memory 606 or persistent storage 608.

[0243] In one example, program code 618 is in a functional form on computer readable medium 620 that is selectively removable and may be loaded onto or transferred to computing device 224 for execution by processor unit 604. In one example, program code 618 and computer readable medium 620 form computer program product 622. Computer readable medium 620 may be computer readable storage medium 624 or computer readable signal medium 626.

[0244] The computer readable storage medium 624 may include, but is not limited to, an optical or magnetic disk that is inserted into or placed into a drive that is part of the persistent storage 608 or other device for transfer to a storage device, such as a hard drive that is part of the persistent storage 608. The computer readable storage medium 624 may take the form of a persistent storage device, such as a hard drive, a thumb drive, a network device, the cloud, flash memory, an optical disk, a magnetic disk, etc. The computer readable storage medium 624 may be connected to or otherwise transferred to the computing device 224.

[0245] In one example, the processes performed by various examples of the disclosed matching apparatus 100 and manufacturing system 168, and the operational steps implemented by various examples of the disclosed methods 1000, 2000, 3000 and / or portions thereof, may be implemented as or utilize a computer program product including a non-transitory computer-readable memory medium and computer control instructions stored on the non-transitory computer-readable memory medium that are executed by a computer processor.

[0246] Accordingly, various implementations of the apparatus, systems, and methods described herein may be realized in digital electronic circuitry, integrated circuits, specially designed ASICs (application-specific integrated circuits), computer hardware, firmware, software, and / or combinations thereof. Various implementations may include implementation in one or more computer programs executable and / or interpretable on a programmable system including at least one programmable processor, which may be special purpose or general purpose, coupled to receive data and instructions from, and transmit data and instructions to, a storage system, at least one input device, and at least one output device.

[0247] A computer program (also referred to as a program, software, software application, or code) comprises machine instructions for a programmable processor and may be implemented in a high-level procedural and / or object-oriented programming language and / or assembly / machine language. As used herein, the terms "machine-readable medium" and "computer-readable medium" refer to any computer program product, apparatus, and / or device (e.g., magnetic disk, optical disk, memory, programmable logic device (PLD)) used to provide machine instructions and / or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term "machine-readable signal" refers to any signal used to provide machine instructions and / or data to a programmable processor.

[0248] While one or more of the examples described herein relate to fully automated manufacturing systems and processes, in one or more other examples, the registration apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 are used with partially automated or manual manufacturing systems and processes, where the fixture 102 is positioned relative to a work station and a manufacturing machine is registered to the fixture 102 to perform one or more manufacturing processes on the workpiece 170. Such manufacturing processes include subtractive machining processes, additive machining processes, and assembly processes performed on the workpiece 170. In one example, the manufacturing processes are performed on post-cured composite materials or other materials. In another example, the manufacturing processes are performed on pre-cured composite materials, such as composite layup processes and composite lamination processes.

[0249] 33 and 34, the example mapping apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 may be used in the context of an aircraft manufacturing and operation method 1100, as illustrated in the flow diagram of FIG. 33 and the aircraft 1200 shown schematically in FIG. 34.

[0250] FIG. 34 is an illustration of an aircraft 1200. The aircraft 1200 includes an airframe 1202 and a number of high-level systems 1204. Examples of the high-level systems 1204 include one or more of a propulsion system 1208, an electrical system 1210, a hydraulic system 1212, and an environmental system 1214. In another example, the aircraft 1200 may include any number of other types of systems, such as a communication system, a guidance system, etc. The workpiece 170 may be any one of a structure, an assembly, a subassembly, a component, and a portion of the airframe 1202 or an interior 1206. For example, the workpiece 170 may be any one of an aircraft spar, an airfoil, a fuselage section, an interior panel, an exterior skin panel, etc.

[0251] As shown in Figure 33, during pre-production, method 1100 may include specification and design of aircraft 1200 (block 1102) and material procurement (block 1104). During production of aircraft 1200, component and subassembly manufacturing (block 1106) and system integration (block 1108) may occur. Aircraft 1200 then undergoes certification and delivery (block 1110) and is placed into service (block 1112). Routine maintenance and service (block 1114) may include modification, reconfiguration, retrofitting, etc., of one or more systems of aircraft 1200.

[0252] Each of the processes of method 1100 shown in Figure 33 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). As used herein, a system integrator may include, but is not limited to, any number of spacecraft manufacturers and major system subcontractors, a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers, and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0253] Examples of the matching apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 shown and described herein may be used during any one or more stages of the manufacturing and service method 1100 shown in the flow diagram of Figure 33. In one example, implementations of the disclosed matching apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 may form part of component and subassembly manufacturing (block 1106) and / or system integration (block 1108). For example, the assembly of the aircraft 1200, airframe 1202, and / or components thereof using implementations of the disclosed matching apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 may correspond to component and subassembly manufacturing (block 1106) and may be prepared in a manner similar to components or subassemblies prepared while the aircraft 1200 is in service (block 1112). Additionally, implementations of the disclosed matching apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 may be utilized during system integration (block 1108) and certification and delivery (block 1110). Similarly, implementations of the disclosed matching apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 may be utilized, for example, but not limited to, during operation of the aircraft 1200 (block 1112) and maintenance and service (block 1114).

[0254] Also with reference to Figures 1 and 34, disclosed are methods of fabricating a portion of aircraft 1200 (Figure 34) using association apparatus 100 (Figure 1) and a method of fabricating a portion of aircraft 1200 using manufacturing system 168 (Figure 1). Also with reference to Figures 29 and 34, disclosed is a portion of aircraft 1200 assembled according to method 1000 (Figure 29). Also with reference to Figures 30 and 34, disclosed is a portion of aircraft 1200 assembled according to method 2000 (Figure 30). Also with reference to Figures 31 and 34, disclosed is a portion of aircraft 1200 assembled according to method 3000 (Figure 31). The portion of aircraft 1200 includes one or more structures, components, parts, assemblies, and subassemblies of any one of airframe 1202, interior 1206, and high-level systems 1204.

[0255] As used herein, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function does not merely have the potential to perform the particular function after further modification, but is actually capable of performing the particular function without any change. In other words, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing that particular function. As used herein, "configured to" refers to an existing characteristic of a system, apparatus, device, structure, article, element, component, or hardware that enables the system, apparatus, device, structure, article, element, component, or hardware to perform a particular function without further modification. For the purposes of this disclosure, a system, apparatus, device, structure, article, element, component, or hardware that is described as "configured" to perform a particular function may additionally or alternatively be described as "adapted" and / or "operating" to perform that function.

[0256] For purposes of this disclosure, the terms "coupled," "coupling," and similar terms refer to two or more elements that are coupled, connected, fastened, attached, connected, in communication with, or otherwise associated (e.g., mechanically, electrically, fluidly, optically, electromagnetically) with one another. In various examples, these elements may be directly associated or indirectly associated. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, through another element C. Not all relationships between the various disclosed elements are necessarily depicted. Thus, other connections may exist than those shown in the figures.

[0257] As used herein, the terms "about" and "approximately" refer to or describe a condition that is close to, but not exactly within, the stated condition, yet still performs a desired function or obtains a desired result. By way of example, the terms "about" and "approximately" refer to a condition that is within a given acceptable tolerance or precision. For example, the terms "about" and "approximately" refer to a condition that is within 10% of the stated condition. However, the terms "about" and "approximately" do not exclude a condition that is exactly within the stated condition.

[0258] In the above-referenced Figures 1, 7, 16, 25, 32, and 34, blocks represent functional elements, features, or components thereof, and lines connecting various blocks do not necessarily imply a particular configuration. Accordingly, modifications, additions, and / or omissions may be made to the illustrated configurations. Furthermore, those skilled in the art will understand that not all elements described and illustrated in the above-referenced Figures 1-29, 32, and 34 need necessarily be included in every example, and not all elements described herein may necessarily be depicted in each example. Unless otherwise specified, the schematic diagrams of the examples illustrated in the above-referenced Figures 1-29, 32, and 34 do not imply architectural limitations with respect to the examples. Rather, it should be understood that one exemplary configuration is shown, which may be modified as appropriate.

[0259] In the above-referenced Figures 29-31 and 33, the blocks represent processes, steps, and / or portions thereof, and the lines connecting various blocks do not imply a particular order or dependency of the processes or portions thereof. It should be understood that not all dependencies between the various disclosed processes are necessarily depicted. Figures 29-31 and 33 and the accompanying disclosure describing the processes of the disclosed methods described herein should not be construed as necessarily dictating the order in which the processes should be performed. Rather, although one exemplary order is shown, it should be understood that the order of the processes may be modified as appropriate. Accordingly, modifications, additions, and / or omissions may be made to the illustrated processes, and certain processes may be performed in a different order or simultaneously. Furthermore, one skilled in the art will understand that not all of the described processes need be performed.

[0260] Furthermore, throughout this specification, references to features, advantages, or similar language as used herein do not imply that all of the features and advantages that may be realized in the examples disclosed herein should or are in any single example. Rather, language referring to features and advantages is understood to mean that the particular feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussions of features, advantages, and similar language as used throughout this disclosure may, but do not necessarily, refer to the same example.

[0261] The described features, advantages, and characteristics of one example may be combined in any suitable manner in one or more other examples. Those skilled in the art will recognize that the examples described herein may be practiced without one or more specific features or advantages of a particular example. In other examples, additional features and advantages may be recognized in a particular example that may not be present in all examples. Furthermore, while various examples of the alignment device 100, manufacturing system 168, and methods 1000, 2000, 3000 have been shown and described, modifications will occur to those skilled in the art upon reading this specification.

[0262] Additionally, the present disclosure includes examples according to the following clauses:

[0263] Terms 1. A correspondence device, comprising: a fixture movable relative to the work cell; an association mechanism fixed to the fixture; a gripper configured to engage the mapping mechanism; and a controller in communication with the gripper; the controller configured to position the fixture relative to the work cell from a gripper position of the gripper engaged with the registration mechanism.

[0264] 2. The apparatus of clause 1, wherein the controller further comprises: determining a gripper position of the gripper in at least one dimension of a fixed coordinate system; determining a position of the mapping mechanism in at least one dimension of the fixed coordinate system from the gripper position of the gripper; and determining a fixture position of the fixture in at least one dimension of the fixed coordinate system from the corresponding mechanism position of the corresponding mechanism; The device being configured.

[0265] 3. The apparatus of clause 2, wherein the controller further comprises: registering a digital model representing the fixture and the reference mechanism to a reference mechanism location of the reference mechanism; and Convert the model position of the digital model registered in the corresponding mechanism position to the fixture position of the fixture. The device being configured.

[0266] 4. The apparatus of clause 2 or 3, wherein the controller is further configured to associate the automated machine with a fixture position of the fixture.

[0267] 5. A device according to clause 4, the fixture includes a mandrel configured to support the pre-cured composite laminate; and an automated machine configured to perform a pre-cure manufacturing process on the pre-cure composite laminate; Device.

[0268] 6. A device according to clause 4 or 5, the fixture includes a retention mechanism configured to secure the post-cured composite structure; and the automated machine is configured to perform a post-cure manufacturing process on the post-cure composite structure; Device.

[0269] 7. A device according to clause 4, 5 or 6, the gripper is coupled to an automated machine; and the automated machine is configured to move the gripper relative to the fixture (102) in at least one dimension of a fixed coordinate system. Device.

[0270] 8. The apparatus of any one of clauses 1 to 7, further comprising a drive assembly coupled to the gripper and configured to move the gripper relative to the fixture.

[0271] 9. The apparatus of clause 8, wherein the gripper is configured to move the fixture inside a work envelope of the work cell.

[0272] 10. A device according to any one of clauses 1 to 9, The mapping mechanism: a plate extending from the fixture; a correspondence indicator portion located on the plate; Includes; The gripper a jaw assembly configured to grasp the plate; a contact index portion coupled to the jaw assembly and configured to engage the interface index portion; Including, Device.

[0273] 11. A method of manufacturing a part of an aircraft using an apparatus according to any one of clauses 1 to 10.

[0274] 12. A manufacturing system preferably comprising a correlation device according to any one of clauses 1 to 10, wherein the manufacturing system: an automated machine located within the work cell and configured to perform at least one manufacturing process; a fixture configured to support a workpiece and movable relative to the work cell; an association mechanism fixed to the fixture; a gripper configured to engage the mapping mechanism; a controller that communicates with the gripper and the automated machine; Including, a controller configured to position the fixture relative to the work cell from a gripper position of the gripper engaged with the mapping mechanism; and The manufacturing system, wherein the controller is further configured to associate an automated machine with a fixture location of the fixture.

[0275] 13. The system of clause 12, wherein the controller further comprises: determining a gripper position of the gripper in at least one dimension of a fixed coordinate system; determining a reference mechanism position of the reference mechanism in at least one dimension of a fixed coordinate system from a gripper position of the gripper; and determining a fixture position of the fixture in at least one dimension of the fixed coordinate system from the corresponding mechanism position of the corresponding mechanism; The system is configured.

[0276] 14. The system of clause 13, wherein the controller further comprises: registering a digital model representing the fixture and the reference mechanism to a reference mechanism location of the reference mechanism; and Convert the model position of the digital model registered in the corresponding mechanism position to the fixture position of the fixture. The system is configured.

[0277] 15. A system according to any one of clauses 12 to 14, comprising: the fixture includes a mandrel configured to support the composite layup; and The system, wherein the automated machine includes an automated fiber placement machine.

[0278] 16. A system according to any one of clauses 12 to 15, comprising: The gripper is connected to an automatic machine, The system, wherein the automated machine is configured to move the gripper relative to the fixture.

[0279] 17. A system according to any one of clauses 12 to 16, comprising: the mapping mechanism includes at least one interface indicator; and the gripper includes at least one contact indicator configured to engage the at least one interface indicator; system.

[0280] 18. The system of any one of clauses 12 to 17, further comprising a vehicle configured to support the fixture and move the fixture relative to the work cell, the vehicle comprising one of an automated guided vehicle and a cart configured to move along a track through the work cell.

[0281] 19. A system according to any one of clauses 12 to 18, comprising: a second work cell; a second automated machine located within the second work cell and configured to perform at least one manufacturing process; a second gripper configured to engage the mapping mechanism; a controller in communication with the second gripper and the second automated machine; the controller is configured to position the fixture relative to the second work cell from a second gripper position of the second gripper engaged with the association mechanism; The controller is further configured to associate a second automated machine with a second fixture position of the fixture. system.

[0282] 20. A method of manufacturing a part of an aircraft using a system according to any one of clauses 11 to 19.

[0283] 21. A manufacturing method comprising: moving the fixture relative to the work cell; engaging an association mechanism with the gripper; positioning the fixture relative to the work cell from a gripper position of the gripper engaged with the mapping mechanism; Corresponding the automated machine to the fixture position of the fixture; A manufacturing method comprising:

[0284] 22. A method according to clause 21, comprising: determining a gripper position of the gripper in at least one dimension of a fixed coordinate system; determining a reference mechanism position of the reference mechanism in at least one dimension of a fixed coordinate system from a gripper position of the gripper; determining a fixture position of the fixture in at least one dimension of the fixed coordinate system from the corresponding mechanism position of the corresponding mechanism; The method further comprises:

[0285] 23. A method according to clause 21 or 22, comprising: gripping the corresponding mechanism with a grip head of a gripper; Engaging at least one interface indicator of the correlation mechanism with at least one contact indicator coupled to the grip head. and

[0286] 24. A part of an aircraft assembled in accordance with the method set out in any one of clauses 20 to 23.

Claims

1. An association device (100), a fixture (102) configured to support a workpiece (170) and movable relative to the work cell (106); a mating mechanism (104) fixed to the fixture (102); a gripper (108) movable relative to the work cell (106) and configured to engage the mapping mechanism; a controller (110) in electrical and / or data communication with the gripper (108); Including, the controller (110) is configured to determine a gripper position (114) of the gripper (108) relative to the work cell (106); the gripper (108) is configured to move the fixture (102) within the work cell (106) while the gripper (108) is engaged with the mapping mechanism (104); To position the fixture (102) with the gripper (108) engaged with the mapping mechanism (104), the controller (110) is further configured to determine a fixture position (118) of the fixture (102) relative to the work cell (106) based on the gripper position (114) of the gripper (108). Apparatus (100).

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

3. 3. The apparatus of claim 2, wherein the controller is configured to load a digital model representing a geometry of the correlation mechanism and the fixture and also representing a geometry of the workpiece, and the controller is further configured to determine the fixture position representing a workpiece position of the workpiece and / or the workpiece position of the workpiece based on the determined correlation mechanism position and the loaded digital model.

4. 4. The device (100) according to claim 2 or 3, The controller (110) further comprises: registering a digital model (120) representing the fixture (102) and the reference feature (104) at the reference feature location (116) of the reference feature (104); and and converting a model position (126) of the digital model (120) registered in the associated mechanism position into the fixture position (118) of the fixture (102). The device (100) is configured.

5. 5. The apparatus (100) of claim 2, 3 or 4, wherein the controller (110) is further configured to associate an automated machine (128) with the fixture location (118) of the fixture (102); the fixture (102) includes a mandrel (130) configured to support a composite laminate; the automated machine (128) is configured to perform a pre-cure manufacturing process on the composite laminate; and / or the fixture (102) includes a retention mechanism (260) configured to secure the post-cured composite structure; the automated machine (128) is configured to perform a post-cure manufacturing process on the post-cure composite structure; Apparatus (100).

6. 6. The device (100) according to any one of claims 1 to 5, The gripper (108) is connected to an automatic machine (128); the automated machine (128) is configured to move the gripper (108) relative to the fixture (102) in at least one dimension of a fixed coordinate system; Apparatus (100).

7. 7. The apparatus of claim 1, further comprising a drive assembly coupled to the gripper and configured to move the gripper relative to the fixture, wherein the gripper is configured to move the fixture inside a work envelope of the work cell.

8. 8. An apparatus according to any one of claims 1 to 7, comprising: The association mechanism: a plate extending from the fixture; an interface indicator located on the plate; and The gripper a jaw assembly configured to grasp the plate; a contact index coupled to the jaw assembly and configured to engage the interface index. Device.

9. an automated machine (128) located within the work cell (106) and configured to perform at least one manufacturing process; The associating device (100) according to any one of claims 1 to 8, Including, the controller (110) is further configured to associate the automated machine (128) with a fixture location (118) of the fixture (102); Manufacturing system.

10. the fixture (102) includes a mandrel (130) configured to support a composite laminate; the automated machine (128) includes an automated fiber placement machine (132); The system of claim 9.

11. 11. The system of claim 9 or 10, further comprising a vehicle (160) configured to support the fixture (102) and move the fixture (102) relative to the work cell, the vehicle (160) comprising one of an automated guided vehicle and a cart (164) configured to move along a track (166) through the work cell.

12. a second work cell (106); a second automated machine (128) located within the second work cell and configured to perform at least one manufacturing process; a second gripper (108) configured to engage the corresponding mechanism; 12. The system of claim 9, further comprising: the controller (110) is in electrical and / or data communication with the second gripper and the second automated machine; the controller (110) is configured to position the fixture relative to the second work cell from a second gripper position (108) of the second gripper engaged with the mapping mechanism; and The controller (110) is further configured to associate the second automated machine with a second fixture position of the fixture. system.

13. moving the fixture (102) relative to the work cell (106); engaging an associated mechanism (104) fixed relative to the fixture (102) with a gripper (108); moving the fixture (102) within the work cell (106) with the gripper (108) while the gripper (108) is engaged with the mapping mechanism (104); determining a gripper position (114) of the gripper (108) relative to the work cell (106) while the gripper (108) is engaged with the mapping mechanism (104); determining a fixture position (118) of the fixture (102) relative to the work cell (106) from the gripper position (114) of the gripper (108); Associating an automated machine (128) with the fixture position (118) determined from the gripper position (114); A manufacturing method comprising:

14. determining the gripper position (114) of the gripper (108) in at least one dimension of a fixed coordinate system (112); determining a reference mechanism position (116) of the reference mechanism in the at least one dimension of the fixed coordinate system from the gripper position (114) of the gripper (108); and / or determining the fixture position of the fixture in the at least one dimension of the fixed coordinate system from the registration feature position of the registration feature. loading a digital model (120) representing the geometry of the alignment mechanism (104) and the fixture (102), and also representing the geometry of a workpiece (170); determining the fixture position (118) representing the workpiece position (262) and / or the workpiece (170) based on the determined associated mechanism position (106) and the loaded digital model (120); 14. The method of claim 13, further comprising:

15. gripping the corresponding mechanism (104) with a gripping head (232) of the gripper (108); Engaging at least one interface indicator (146) of said addressing mechanism (104) with at least one contact indicator coupled to said grip head (232). The method of claim 13 or 14, further comprising:

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