Mapping device and mapping method

Abstract

To provide an indexing apparatus and a method of indexing during a production process.SOLUTION: An indexing apparatus 100 includes a fixture tool 102 movable relative to an operation cell 106, and an indexing feature 104 fixed relatively to the fixture tool 102. The indexing apparatus 100 also includes a sensor, configured to detect the indexing feature 104. The indexing apparatus 100 further includes a controller 110 in communication with the sensor. The controller 110 is configured to locate the fixture tool 102 relative to the operation cell 106 from an indexing-feature location 116 of the indexing feature 104, identified by the sensor.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure generally relates to manufacturing. More specifically, it relates to an association device and an association method during a manufacturing process.

Background Art

[0002] Many structures, parts, and components have a fixed base and are manufactured using large automated machines that operate along a predetermined tool path under computer control.

[0003] The abstract of U.S. Patent No. 9,817,402 states that "for automation at the work cell and factory levels, it is necessary for an automated guided vehicle (AGV) to achieve high required position accuracy and reproducibility with respect to a cradle stand or maintenance stand within the work cell. The AGV uses a laser scanner sensor to measure the distance to an object within the work cell. It filters the distance measurements of objects that are not the target shape of the stand or maintenance stand. It removes systematic or bias errors of the laser scanner sensor from the filtered distance measurements and applies a mathematical filter or estimation to the filtered distance measurements using the random errors of the laser scanner sensor to generate an evaluated distance measurement. Then, it constructs a map of the target shape using the evaluated distance measurement and uses the map for path planning navigation control of the AGV with respect to the stand or maintenance stand within the work cell."

[0004] The abstract of EP No. 3653369 states: "A manufacturing system comprises a plurality of lamination heads and a head movement system that defines a continuous loop-shaped lamination path and moves the lamination heads continuously along the lamination path. The manufacturing system further comprises at least one lamination mandrel positioned along a portion of the lamination path. While the lamination heads are moved by the head movement system to complete one or more revolutions of the lamination path, each lamination head is configured to lay up a composite laminate by discharging layup material onto at least one of the lamination mandrels or onto layup material previously placed on the lamination mandrel."

[0005] The abstract of EP No. 3733387 states: "A reinforced composite placement system is disclosed. The reinforced composite placement system includes a longitudinal end effector having a first mounting point and a second mounting point; a first rotating arm having a first connector configured to connect to the first mounting point; a first moving system configured to move the first rotating arm in a manufacturing environment; a second rotating arm having a second connector configured to connect to the second mounting point; and a second moving system configured to move the second rotating arm in a manufacturing environment."

[0006] Such manufacturing techniques require precise mapping of the workpiece to the machine. One method of mapping is to probe the workpiece at various positions and, based on the probed positions, align the machine's working tool to the nearest position to the workpiece, i.e., "zero." Another method of mapping is to use fixtures to fix the workpiece in a specific repeatable position. However, both methods can be time-consuming and costly processes, requiring extensive setup each time the workpiece is moved to a new working position or a new workpiece is moved to the aforementioned working position. In large structures such as aircraft wing spars, airfoils, and fuselage sections, this problem is amplified, sometimes requiring a very large number of probe positions or very large fixtures. Furthermore, neither of these methods is suitable for continuous manufacturing where it is necessary to move the workpiece quickly and accurately from one working position to another. Therefore, those skilled in the art will continue research and development in the field of mapping during manufacturing and will thus find usefulness in devices and methods to address the above concerns. [Overview of the project]

[0007] The following is a non-exclusive list of examples of subject matter covered by this disclosure, some of which may or may not be claimed.

[0008] In one example, the disclosed mapping device includes a movable fixture relative to a work cell and a mapping mechanism fixed to the fixture. The mapping device also includes a sensor configured to detect the mapping mechanism. The mapping device further includes a controller that communicates with the sensor. The controller positions the fixture relative to the work cell from the mapping mechanism position of the mapping mechanism identified by the sensor. (location) It is configured to be such that

[0009] In one example, the disclosed manufacturing system includes an automated machine located within a work cell and configured to perform at least one manufacturing step. The manufacturing system also includes a fixture configured to support a workpiece and movable relative to the work cell, and a mapping mechanism fixed to the fixture. The manufacturing system further includes a sensor configured to detect the mapping mechanism. The manufacturing system also includes a controller that communicates with the sensor and the automated machine. The controller is configured to position the fixture relative to the work cell from the mapping mechanism position of the mapping mechanism, which is identified by the sensor. The controller is also configured to map the automated machine to the fixture position of the fixture.

[0010] In one example, the disclosed manufacturing method includes (1) moving a fixture relative to a work cell; (2) detecting a mapping mechanism with a sensor; (3) positioning the fixture relative to the work cell from the mapping mechanism position identified by the sensor; 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 claims. [Brief explanation of the drawing]

[0012] [Figure 1] This is a schematic block diagram of an example of a mapping device. [Figure 2] This is a schematic perspective view of an example of a manufacturing system using a matching device. [Figure 3] This is a schematic perspective view of an example of an interface device, mapping mechanism, and mounting fixture for a mapping device. [Figure 4] This is a schematic plan view of an example of a correspondence device. [Figure 5] This is a schematic plan view of an example of a correspondence device. [Figure 6] This is a schematic plan view of an example of a correspondence device. [Figure 7] It is a schematic block diagram of an example of a processing step used to determine the position of the fixture of the association device. [Figure 8A] It is a schematic perspective view of an example of the gripper of the interface device of the association device. [Figure 8B] It is a schematic perspective view of an example of the association mechanism of the association device. [Figure 9A] It is a schematic perspective view of an example of the gripper of the interface device of the association device. [Figure 9B] It is a schematic perspective view of an example of the association mechanism of the association device. [Figure 10] It is a schematic perspective view of an example of a manufacturing system. [Figure 11] It is a schematic perspective view of an example of a manufacturing system using the association device. [Figure 12] It is a schematic plan view of an example of the association device. [Figure 13] It is a schematic perspective view of an example of the interface device, the association mechanism, and the fixture of the association device. [Figure 14] It is a schematic plan view of an example of the association device. [Figure 15] It is a schematic plan view of an example of the association device. [Figure 16] It is a schematic block diagram of an example of a processing step used to determine the position of the fixture of the association device. [Figure 17] It is a schematic perspective view of an example of the association mechanism and the fixture of the association device. [Figure 18] It is a schematic perspective view of an example of the association mechanism and the fixture of the association device. [Figure 19] It is a schematic perspective view of an example of the association mechanism and the fixture of the association device. [Figure 20] It is a schematic perspective view of an example of a manufacturing system. [Figure 21] It is a schematic perspective view of an example of a manufacturing system using the association device. [Figure 22] It is a schematic plan view of an example of the association device. [Figure 23] It is a schematic perspective view of an example of an interface device, an association mechanism, and a fixture of an association device. [Figure 24] It is a schematic block diagram of an example of a processing step used to determine the position of a fixture of an association device. [Figure 25] It is a schematic elevation view of an example of an association mechanism and a fixture of an association device. [Figure 26] It is a schematic elevation view of an example of an association mechanism and a fixture of an association device. [Figure 27] It is a schematic elevation view of a partial cross-section showing an example of a probe of an interface device, an association mechanism, and a fixture of an association device. [Figure 28] It is a schematic perspective view of an example of a manufacturing system. [Figure 29] It is a flowchart of an example of a manufacturing method. [Figure 30] It is a flowchart of an example of a manufacturing method. [Figure 31] It is a flowchart of an example of a manufacturing method. [Figure 32] It is a schematic block diagram of an example of a controller of an association device. [Figure 33] It is a flowchart of a method for manufacturing and maintaining an aircraft. [Figure 34] It is a block diagram of an aircraft.

Mode for Carrying Out the Invention

[0013] The following detailed description refers to the accompanying drawings that illustrate specific examples described by the present disclosure. Other examples having different structures and processes are not outside the scope of the present disclosure. In different drawings, the same reference numerals may refer to the same mechanism, element, or component.

[0014] Exemplary and non-exclusive examples of the subject matter of this disclosure are provided below, which may or may not be claimed. Where the “Example” is used herein, it means that one or more mechanisms, structures, elements, components, features, and / or operating steps described in relation to the example are included in at least one embodiment and / or implementation of the subject matter of this disclosure. Thus, throughout this disclosure, the phrases “an example,” “another example,” “an example,” and similar wording may, but may not, refer to the same example. Furthermore, the subject matter of the invention characterizing any example may, or may not, include the subject matter of the invention characterizing any other example. Furthermore, the subject matter of the invention characterizing any example may, or may not, be combined with the subject matter of the invention characterizing any other example.

[0015] As an example, with a rough reference to Figure 1-33, this disclosure describes a matching device 100 used to position and match a workpiece 170 during the manufacturing process, a manufacturing system 168 utilizing the matching device 100, and manufacturing methods 1000, 2000, and 3000 for positioning and matching a workpiece 170 using the matching device 100.

[0016] Figure 1 schematically illustrates an example of a mapping device 100. Generally, the mapping device 100 provides a means for accurately and repeatedly determining the position of a workpiece 170 relative to a reference frame 216 defined by a fixed coordinate system 112. Figure 1 also schematically illustrates an example of a manufacturing system 168 including the mapping device 100. The manufacturing system 168 includes or forms at least a part of a work cell 106. An automated machine 128 is located 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 a fixed coordinate system 112 and includes a work envelope 140. The work envelope 140 forms a three-dimensional volume within the work cell 106, described by the fixed coordinate system 112, on which the automated machine 128 operates.

[0017] Referring to Figure 1, the mounting device 100 includes a fixture 102. The fixture 102 is configured to securely hold the workpiece 170. The fixture 102 includes various suitable holding mechanisms 260 that enable the workpiece 170 to be fixed to or otherwise held by the fixture 102. The fixture 102 is movable relative to the work cell 106, for example, to an automated machine 128 located within the work cell 106. For example, the fixture 102, together with the workpiece 170 fixed to the fixture 102, is moved to a working position 258 within the work envelope 140 of the work cell 106.

[0018] As used herein, the term “working position 258” typically refers to the spatial position of the fixture 102, and by extension, the workpiece 170, when the fixture 102 is moved within the work cell 106 for the automatic machine 128 to perform at least one manufacturing step on the workpiece 170. In this disclosure, it is recognized and taken into consideration that the working position 258 may not be precisely known when the fixture 102 is moved within the work cell 106. Therefore, the matching device 100 is configured to determine the position of the fixture 102 relative to the reference frame 216 (also referred to herein as the fixture position 118), and by extension, the position of the workpiece 170 (also referred to herein as the workpiece position 262), when the fixture 102 is in the working position 258.

[0019] The matching device 100 includes a matching mechanism 104. The matching mechanism 104 is fixed to the mounting fixture 102. In other words, the position of the matching mechanism 104 relative to the mounting fixture 102 is constant regardless of the position (or change in position) of the mounting fixture 102 relative to the reference frame 216. In one example, the matching mechanism 104 is connected to the mounting fixture 102. In another example, the matching mechanism 104 is positioned on the mounting fixture 102. In yet another example, the matching mechanism 104 forms part of the mounting fixture 102 (for example, integrally with it).

[0020] Throughout this disclosure, the term “position” refers to the linear position of an object along one or more orthogonal axes in three-dimensional space, for example, along a fixed coordinate system 112. In addition, in some examples, the term “position” also refers to the angular position (e.g., orientation) of an object around one or more orthogonal axes in three-dimensional space, for example, around a fixed coordinate system 112. Generally, the “position” of an object refers to the X position of at least a portion of one or more outer surfaces of the object (e.g., the X coordinates of several points representing at least a portion of the outer surface), the Y position of at least a portion of one or more outer surfaces of the object (e.g., the Y coordinates of several points representing at least a portion of the outer surface), and the Z position of at least a portion of one or more outer surfaces of the object (e.g., the Z coordinates of several points representing at least a portion of the outer surface).

[0021] Referring further to Figure 1, the mapping device 100 includes an interface device 220. The interface device 220 is configured to interface with the mapping mechanism 104 and to position the mapping mechanism 104 relative to a reference frame 216, such as within the work cell 106. The interface device 220 is configured to generate interface data 222 representing the position of the mapping mechanism 104 relative to the reference frame 216 (also referred to herein as the mapping mechanism position 116). As will be described in detail herein, the interface device 220 can interface with and position the mapping mechanism 104 using at least one of the gripper 108, the sensor 184, and a plurality of probes 202.

[0022] The mapping device 100 also includes a controller 110. The controller 110 communicates (e.g., telecommunications and / or data communications) with the interface device 220. The controller 110 is configured to process interface data 222 generated by the interface device 220 and to determine the mapping mechanism position 116 based on the interface data 222. The controller 110 is also configured to determine the immediate (e.g., real-time, actual) position of the fixture 102, and thus the workpiece 170, relative to the reference frame 216, based on the mapping mechanism position 116. The automated machine 128 is mapped to the fixture 102 based on this determined position of the fixture 102 (fixture position 118).

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

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

[0025] Therefore, the mounting mechanism position 116 can be used to determine the mounting fixture position 118. Then, the mounting fixture position 118 can be used to assume that the workpiece position 2622 is within tolerance. In other words, the mounting fixture position 118 represents the immediate position of the mounting fixture 102 and the workpiece 170 relative to the reference frame 216. Thus, throughout this disclosure, unless otherwise specified, the term “mounting 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, the mapping mechanism 104, and the workpiece 170 on which the manufacturing process will be performed, before the start of the positioning and mapping process. In one example, the type of fixture, the type of mapping mechanism, and / or the type of workpiece can be loaded into the program before the execution of the positioning and mapping command. In another example, the program can actively identify and select the type of fixture, the type of mapping mechanism, and / or the type of workpiece from an optional database based on one or more predetermined selection criteria.

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

[0028] In one example, the digital model 120 includes a digital representation of the mounting fixture 102, the matching mechanism 104, and the workpiece 170. In another example, the digital model 120 includes a digital representation of the combination of the mounting fixture 102, the matching mechanism 104 fixed to the mounting fixture 102, and the workpiece 170. Thus, the digital model 120 represents the position of the matching mechanism 104 and / or the workpiece 170 relative to the mounting fixture 102.

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

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

[0031] In one example, the automated machine 128 includes a multi-degree-of-freedom robotic arm 226 and an end effector 228 connected to the working end of the robotic arm 226. The end effector 228 includes or takes the form of at least one working tool configured to perform at least one manufacturing step on the workpiece 170. The robotic arm 226 is configured to move the end effector 228 along a predetermined toolpath relative to the fixture 102 and the workpiece 170 under computer control, based on the fixture position 118.

[0032] In general, the positioning and alignment steps described herein can be performed in combination with, or as the first step related to, any one of various types of addition or removal processes. Thus, the automatic machine 128 can perform drilling, milling, fastening, Before curing and / or After curing Any one of various types of manufacturing processes, including but not limited to composite material assembly processes (e.g., material layup processes, lamination processes, etc.), can be performed on the workpiece 170. Generally, the end effector 228 includes appropriate tools configured to perform the relevant manufacturing process.

[0033] Since the geometry of the workpiece 170 is known, and it is assumed that the position of the workpiece 170 is known or within tolerance relative to the fixture 102, associating the automated machine 128 with the fixture 102 based on the fixture position 118 results in associating the automated machine 128 with the workpiece 170. Once the automated machine 128 is associated with the fixture position 118, it operates along the programmed toolpath and performs at least one manufacturing step on the workpiece 170 in a known manner. The geometry of the workpiece 170 and its known position relative to the fixture 102 are incorporated into and described in the programmed toolpath of the automated machine 128.

[0034] This disclosure acknowledges and considers that the geometry of the workpiece 170 may change as a result of manufacturing processes (e.g., assembly or machining) performed on the workpiece 170. However, the position of the workpiece 170 relative to the fixture 102 and the matching mechanism 104 will not change due to actions other than the manufacturing process. Therefore, any distortion or movement of the workpiece 170 will be within the tolerances of the manufacturing process and will not affect the position of the workpiece 170 to an out-of-tolerance extent. In other words, at each stop along the complete manufacturing process, the only change in the workpiece 170 is the change in geometry due to the various manufacturing processes.

[0035] Changes in the geometry of the workpiece 170 resulting from some manufacturing process are either 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., represented by the digital model 120) is updated based on addition or subtraction processes performed on the workpiece 170.

[0036] When the fixture 102 and the workpiece 170 are moved by the second automatic machine 174 (Figures 10, 20, and 28) to a subsequent working position 258, such as the second working cell 172, for the execution of subsequent manufacturing processes on the workpiece 170, the mapping mechanism 104 is positioned so that the fixture position 118 is determined and the second automatic machine 174 is mapped to the fixture position 118 as described herein. The known (e.g., modified) geometry of the workpiece 170 and the known position of the workpiece 170 relative to the fixture 102 are incorporated into and described in the programmed toolpath of the second automatic machine 174. Thus, such changes to the workpiece geometry 268 are taken into account in the subsequent positioning and mapping processes, thereby enabling repeatable mapping based on the position of the fixture 102.

[0037] Accordingly, the examples of the matching apparatus 100, manufacturing system 168, and methods 1000, 2000, and 3000 disclosed herein enable the workpiece 170 to be positioned quickly and accurately without requiring costly and time-consuming setup or positioning processes. Similarly, the automated machine 128 can be quickly and accurately associated with the fixture 102, and by extension with the workpiece 170, based on the predetermined position of the fixture 102.

[0038] Figure 1-29 schematically illustrates various implementation examples of the interface device 220 and the mapping mechanism 104 of the disclosed mapping device 100. As shown in Figure 1-10, the interface device 220 includes at least one gripper 108 that provides a contact interface with the mapping mechanism 104. As shown in Figure 11-21, in one example, the interface device 220 includes at least one sensor 184 that provides a non-contact interface with the mapping mechanism 104. As shown in Figure 22-29, in one example, the interface device 220 includes a plurality of probes 202 that provide a contact interface with the mapping mechanism 104.

[0039] Referring broadly to Figure 1 and especially Figure 2-4, in one example the matching device 100 includes a mounting fixture 102. The mounting fixture 102 is movable relative to the work cell 106. The matching device 100 also includes a matching mechanism 104. The matching mechanism 104 is fixed to the mounting fixture 102. For example, the matching mechanism 104 is connected to the mounting fixture 102. In one example, the matching mechanism 104 extends from the mounting fixture 102.

[0040] In the example shown in Figure 2-5, the matching mechanism 104 is connected to the front end of the mounting fixture 102 and extends from there. In other examples, the matching mechanism 104 is connected to or located on another part of the mounting fixture 102 (e.g., the side, back, or bottom of the mounting fixture 102).

[0041] In one example, the mapping device 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 with (for example, to be in physical contact with) the mapping mechanism 104. The mapping mechanism 104 is appropriately positioned relative to the fixture 102 such that at least a portion of the mapping mechanism 104 is physically accessible by the gripper 108. Conversely, the gripper 108 is appropriately positioned relative to the fixture 102 such that at least a portion of the gripper 108 is physically accessible by the mapping mechanism 104. With the gripper 108 engaged with the mapping mechanism 104, the position of the gripper 108 (also referred to herein as the gripper position 114) (Figure 1) represents or corresponds to the mapping mechanism position 116 (Figure 1). In other words, the gripper 108 positions the mapping mechanism 104 within the reference frame 216.

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

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

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

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

[0046] Referring to Figure 5, in one example, the joint mechanism 230 is separate from and independent of the automatic machine 128. In this example, the entire range of motion, or any degree of freedom, of the gripper 108 is provided by the joint mechanism 230 (for example, specific to the joint mechanism 230).

[0047] Referring to Figure 6, in another example of the mapping device 100, the interface device 220 (Figure 1) includes two or more grippers 108 (hereinafter referred to as multiple grippers 108). In this example, the mapping device 100 includes two or more mapping mechanisms 104 (hereinafter referred to as multiple mapping mechanisms 104). Each of the mapping mechanisms 104 is fixed to the fixture 102. Each of the grippers 108 is configured to engage with and position one of the corresponding mapping mechanisms 104.

[0048] Referring to Figure 1-6, the mapping device 100 also includes a controller 110. The controller 110 communicates 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 the gripper position 114 of the gripper 108, while the gripper 108 is engaged with the mapping mechanism 104.

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

[0050] In one example, the controller 110 is configured to register a digital model 120 (Figure 1) representing the mounting fixture 102 and the mapping mechanism 104 at the mapping mechanism position 116 of the mapping mechanism 104. The controller 110 is also configured to convert the model position 126 of the digital model 120 registered at the mapping mechanism position 116 to the mounting fixture position 118 of the mounting fixture 102.

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

[0052] Referring to Figure 2-6, in one example, when the gripper 108 (e.g., grip head 232) is engaged with the mapping mechanism 104, there is at least one contact point between the gripper 108 and the mapping mechanism 104. This contact point has XYZ coordinates common to both the gripper 108 and the mapping mechanism 104. The gripper position data 238 (Figure 16) represents the XYZ coordinates of the contact point of the gripper 108, and the gripper position 114 is described by the XYZ coordinates of the contact point of the gripper 108. The controller 110 converts the XYZ coordinates of the contact point of the gripper 108 to the XYZ coordinates of the corresponding contact point of the mapping mechanism 104. Then, the controller 110 determines the mapping mechanism position 116, which is described by the XYZ coordinates of the contact point of the mapping mechanism 104.

[0053] In one example, the gripper 108 (e.g., grip head 232) and the matching mechanism 104 include multiple contact points. Therefore, the gripper position 114 is described by the XYZ coordinates of the multiple contact points of the gripper 108, and the matching mechanism position 116 is described by the XYZ 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 matching mechanism 104 will yield a greater number of XYZ coordinate data points for processing, resulting in improved accuracy of the matching mechanism position 116 and the fixture position 118 during the alignment of data points in the matching process. In one example, the gripper 108 (e.g., grip head 232) and the matching mechanism 104 include at least three contact points.

[0055] Referring briefly to Figures 8A, 8B, 9A, and 9B, in one example, the gripper 108 (e.g., grip head 232) includes at least one contact-index 148 (Figures 8A and 9A), and the mapping mechanism 104 includes at least one interface-index 146 (Figures 8B and 9B). With the gripper 108 (e.g., grip head 232) engaged with the mapping mechanism 104, the contact-index 148 engages with 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 XYZ coordinates common to both the contact-index 148 and the interface-index 146. The gripper position data 238 represents the XYZ coordinates of the contact point of the contact-index 148, and the gripper position 114 is described by the XYZ coordinates of the contact point of the contact-index 148.

[0056] The controller 110 converts the XYZ coordinates of the contact point of the contact indicator unit 148 to the XYZ coordinates of the corresponding contact point of the interface indicator unit 146. The controller 110 determines the corresponding mechanism position 116, which is described by the XYZ coordinates of the contact point of the interface indicator unit 146.

[0057] Generally, the gripper 108 (e.g., grip head 232) includes multiple contact indicators 148, and the mapping mechanism 104 includes multiple interface indicators 146, resulting in multiple contact points. Therefore, the gripper position data 238 (Figure 7) represents the XYZ coordinates of the multiple contact points of the contact indicators 148 of the gripper 108. The gripper position 114 is described by the XYZ coordinates of the contact points of the contact indicators 148 of the gripper 108. The mapping mechanism position 116 is described by the XYZ coordinates of the corresponding multiple contact points of the interface indicators 146.

[0058] In one example, the gripper 108 (e.g., grip head 232) includes at least three contact indicators 148, and the matching mechanism 104 includes at least three interface indicators 146, resulting in at least three contact points. In other examples, the gripper 108 (e.g., grip head 232) may include fewer or more contact indicators 148, and the matching mechanism 104 may include fewer or more 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 matching mechanism 104, which in turn increases the number of XYZ coordinate data points for processing, thereby improving the accuracy of the matching mechanism position 116 and the mounting fixture position 118 during the alignment of data points in the matching process.

[0060] Referring again to Figure 7, the controller 110 is configured to register a digital model 120 representing the mounting fixture 102 and the mapping mechanism 104 at the mapping mechanism position 116 and to determine the model position 126. In one example, the controller 110 is configured to align the digital model 120 with the XYZ coordinates describing the mapping mechanism position 116 within the reference frame 216. The digital model 120 includes data points representing the contact points of the mapping mechanism 104. For example, the digital model 120 includes data points representing the interface index portion 146 of the mapping mechanism 104. In one example, the controller 110 performs a best-fit process (for example, by performing a best-fit algorithm) to align the data points representing the contact points of the mapping mechanism 104, for example, the data points representing the interface index portion 146, with the data points representing the XYZ coordinates describing the mapping mechanism position 116. In one example, the best-fit process includes a rigid body point cloud transformation operation.

[0061] Once the digital model 120 is registered and aligned with the corresponding mechanism position 116, the controller 110 is configured to convert the model position 126 to, for example, the fixture position 118 of the fixture 102 relative to the reference frame 216. For example, the fixture position 118 is assumed to be the same as the model position 126 within tolerance. Therefore, the fixture position 118 represents the most recent (e.g., current, real-time) position of the fixture 102, and consequently the workpiece 170, relative to the work cell 106 and the automatic machine 128.

[0062] If the fixture position 118 is known, the automated machine 128 is associated with or "set to zero" the fixture position 118 and performs the manufacturing process on the workpiece 170 according to a predetermined toolpath. Based on the fixture position 118, the automated machine 128 is associated with the fixture 102, and consequently, the automated machine 128 is associated with 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 described in the programmed toolpath of the automated machine 128.

[0063] Referring to Figures 1 and 2, in one example, the mapping device 100 includes an automatic machine 128. The automatic machine 128 is located within the work cell 106 and communicates with the controller 110. The controller 110 is configured to map the automatic machine 128 to the mounting position 118 of the mounting fixture 102.

[0064] Referring to Figures 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 of the automated machine 128, i.e., one or more degrees of freedom. In one example, a robot arm 226 is connected to the gantry 134. In one example, the gantry 134 is a movable overhead gantry within the work cell 106 to move the robot 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 working position 258 within the work cell 106, and the gantry 134 and / or robot arm 226 move relative to the fixture 102 so that the end effector 228 follows a predetermined toolpath.

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

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

[0067] Referring to Figures 1 and 2, in one example the manufacturing process includes a composite material layup process and / or a composite material lamination process, Before curing Performed on composite materials Before curing This includes composite material assembly processes or other additional processing processes.

[0068] In this example, the workpiece 170 is Before curing The composite laminate includes (e.g., a layup of pre-impregnated composite material). The fixture 102 includes or takes the form of a mandrel 130. The mandrel 130 is configured to support the composite laminate (workpiece 170). The automatic machine 128 is directed toward the composite laminate (workpiece 170). Before curing It is configured to carry out a manufacturing process. For example, the automated machine 128 includes or takes the form of an automated fiber placement machine 132 (Figure 1).

[0069] In one or more other examples, the manufacturing process includes other additive processes such as assembly processes or subtractive processes such as machining. In such examples, the workpiece 170 is After curing It is one of a composite material structure, a metal structure, a plastic structure, or another non-composite material structure. The fixture 102 includes at least one holding mechanism 260 (Figure 1) configured to secure the workpiece 170 to the fixture 102 during transfer to the work cell 106 and during the manufacturing process. The automated machine 128 is configured to perform at least one of an additive machining process and a subtractive machining process on the workpiece 170. In one example, the automated machine 128 is: After curing For composite material structures After curingIt is configured to carry out a manufacturing process. For example, the automated machine 128 includes or takes the form of any suitable machine tool 270 (Figure 1).

[0070] In one or more examples, any one of the various manufacturing processes described herein is part of a continuous flow manufacturing process. For example, the fixture 102 and the workpiece 170 are pulsed into one of a plurality of work cells that form a continuous flow manufacturing system. In any one of the plurality of work cells, the manufacturing process forms part of the continuous flow manufacturing process. In one example, the manufacturing process is: Before curing The process includes arranging one or more plies of composite material to partially form a composite laminate. In one example, the manufacturing process involves the secondary structure After curing This includes assembly or installation onto composite or non-composite material structures. For example, the manufacturing process may include: After curing This includes machining one or more mechanisms of a composite material structure or a non-composite material structure.

[0071] In one example, the fixture 102 is moved to the working position 258, and the nearest position of the fixture 102 and the workpiece 170 (e.g., the fixture position 118) is determined using the gripper 108 and the matching 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 automatic fiber placement machine 132 laps and / or compacts at least a portion of at least one layer of the composite sheet stack.

[0072] Referring to Figures 2 and 4-6, in one example the mapping device 100 includes a drive assembly 138 connected to the gripper 108. The drive assembly 138 is configured to move the gripper 108 relative to the reference frame 216 in at least one dimension of the fixed coordinate system 112, for example. In one example, the drive assembly 138 is connected 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 automatic machine 128, as illustrated in Figures 5 and 6. In another example, the drive assembly 138 is connected to or formed by the automatic machine 128, such as in an example where the gripper 108 is connected to the automatic machine 128, as illustrated in Figures 2 and 4.

[0073] Referring to Figure 1, in one example, the gripper 108 is configured to move the fixture 102 inside the work envelope 140 of the work cell 106. In one example, the fixture 102 and the workpiece 170 are moved to an initial pre-working position, for example, a position close to (e.g., that position or nearby) the work position 258 (e.g., outside the work cell 106). The computer-controlled gripper 108 moves to engage with the mapping mechanism 104. While engaged with the mapping mechanism 104, the gripper 108 moves the fixture 102 and the workpiece 170 to the work position 258 (e.g., inside the work cell 106). In this way, the fixture 102 and the workpiece 170 are moved to the work position 258 while the fixture position 118 is determined as described above. This combined process further improves the cycle time of the manufacturing process by enabling the movement of the fixture 102 and the workpiece 170 and the positioning of the fixture 102 and the workpiece 170 to be performed substantially simultaneously.

[0074] In another example, the mounting device 100 is separate from the gripper 108 and includes an independent moving mechanism (not shown) configured to move the fixture 102 to the working position 258. In this example, the fixture 102 and the workpiece 170 are moved to a pre-working position, and the independent moving mechanism, which operates under computer control, moves the fixture 102 and the workpiece 170 to the working position 258.

[0075] Figures 8A, 8B, 9A, and 9B schematically show examples of a gripper 108 and a matching mechanism 104. In one example, the gripper 108 (e.g., grip head 232) includes a jaw assembly 144 (Figures 8A and 9A). The jaw assembly 144 is configured to grasp, hold, tighten, or otherwise securely hold at least a portion of the matching mechanism 104 (Figures 8B and 9B). In one example, the matching mechanism 104 is connected to a fixture 102 (not shown in Figure 8B) and includes a plate 150 extending therefrom. The contact indicator 148 (Figures 8A and 9A) and the interface indicator 146 (Figures 8B and 9B) are configured to contact and interlock with each other when the gripper 108 (e.g., jaw assembly 144) properly engages with the matching mechanism 104 (e.g., plate 150).

[0076] Referring to Figures 8A and 8B, in one example, the jaw assembly 144 includes a first jaw and a second jaw. The first and second jaws are movable relative to each other to selectively engage (e.g., grip) with the plate 150. In one example, the jaw assembly 144 includes a stationary first (e.g., upper) jaw and a second (e.g., lower) jaw that is movable relative to the first jaw. In one example, each jaw of the jaw assembly 144 has a substantially planar engagement surface configured to reliably contact one of the corresponding opposing planar engagement surfaces of the plate 150. Other configurations of the jaw assembly 144 and the plate 150 are also possible.

[0077] In one example, the contact indicator 148 (Figure 8A) is connected to or positioned on the jaw assembly 144, and the interface indicator 146 (Figure 8B) is connected to or positioned on the plate 150. The contact indicator 148 is appropriately positioned and configured to engage with the interface indicator 146 when the jaw assembly 144 grips the plate 150. In one example, the contact indicator 148 is positioned on and protruding from the engagement surface of one of the jaws of the jaw assembly 144 (e.g., the upper jaw), and the interface indicator 146 is positioned on and protruding from one of the engagement surfaces of the plate 150.

[0078] In one example, the contact indicator portion 148 includes or takes the form of at least one contact structure 154. The interface indicator portion 146 includes or takes the form of at least one interface structure 152. In one example, the interface structure 152 and the contact structure 154 have complementary geometric shapes and dimensions, so that corresponding surfaces of the contact structure 154 (e.g., forming the contact indicator portion 148) and the interface structure 152 (e.g., forming the interface indicator portion 146) are in contact when the grip head 232 properly engages with the matching mechanism 104. Each of the contact structure 154 and the interface structure 152 includes or takes the form of one of a variety of structural configurations or arrangements.

[0079] 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 projection formed on the surface of the grip head 232 (e.g., protruding therefrom), and the interface structure 152 includes or takes the form of an opening formed on the surface of the plate 150 (e.g., arising therefrom). In this example, the interface structure 152 is configured to receive and engage 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 projection. For example, the projection may be a pin, a spring-loaded ball bearing, or other projection, and the opening may be a hole, a detent, a recess, or other opening, or take the form of.

[0080] Referring to Figures 9A and 9B, in another example, the interface structure 152 of the interface indicator 146 includes or takes the form of a tooling ball protruding from the plate 150. The contact structure 154 of the contact indicator 148 includes or takes the form of a cooperating guide hole, which is formed by the jaw assembly 144 and is configured to receive and mate with the tooling ball when the grip head 232 properly engages with 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.

[0081] Other structural configurations and / or arrangements of the contact indicator portion 148 (e.g., contact structure 154) and interface indicator portion 146 (e.g., interface structure 152) are also possible, such as a cooperating complementary cup and cone configuration.

[0082] In general, any suitable configuration or arrangement of the contact index section 148 and interface index section 146 may be used such that there are at least three contact points between the gripper 108 and the mapping mechanism 104 that can be used to generate at least three data points representing at least three XYZ coordinates of the mapping mechanism 104. In most cases, three data points are sufficient to generate the complete three-dimensional position of the fixture 10 during the positioning and mapping process described above.

[0083] In one example, the XZY coordinate positions of at least two contact indicator parts 148 (e.g., at least two contact structures 154) differ in at least two dimensions of the fixed coordinate system 112. Similarly, the XZY coordinate positions of at least two interface indicator parts 146 (e.g., at least two interface structures 152) differ in at least two dimensions of the fixed coordinate system 112.

[0084] In the implementation example of the positioning and matching process described above, the fixture 102, and consequently the workpiece 170, is moved to the working position 258 for engagement of the matching mechanism 104 by the gripper 108. With the fixture 102 at the working position 258, the position of the matching mechanism 104 with respect to the reference frame 216 is either substantially known or estimated within an acceptable tolerance, allowing the gripper 108 to move to a pre-engagement position with respect to the matching mechanism 104 under computer control. Subsequently, the controller 110 performs a search process in which the gripper 108 moves stepwise along a predefined search path to find the interface indicator 146 and aligns and engages the contact indicator 148 and the interface indicator 146. With the contact indicator 148 and the interface indicator 146 properly aligned and engaged with each other, the contact indicator 148 and the interface indicator 146 share a contact point, and the positioning and matching process is performed as described above.

[0085] Referring to Figures 8A and 9A, in one example the gripper 108 includes at least one engagement sensor 240. The engagement sensor 240 is configured to determine when the gripper 108 is properly aligned and engaged with the matching mechanism 104 (for example, when the contact indicator 148 and the interface indicator 146 are properly aligned and fitted together). The engagement sensor 240 includes or takes the form of one of various types of suitable sensors, such as a depth gauge, pressure sensor, tooling probe, or displacement sensor.

[0086] Referring to Figure 1-6, in one example, the alignment device 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 working position 258 where the gripper 108 engages with the alignment mechanism 104, thereby performing the positioning and alignment process 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 with the alignment mechanism 104, thereby performing the movement, positioning, and alignment process described above.

[0087] Referring to Figure 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 travel path under computer control. In this example, the work cell 106 may include one or more of sensors, guide tapes, guide wires, laser targets, and any other suitable navigation mechanisms for moving the automated guided vehicle 162 along the predetermined travel path. In this example, the automated guided vehicle 162 moving along the predetermined travel path is configured to move the mounting fixture 102 to the working position 258 (or pre-work position) so that the gripper 108 finds and engages with the matching mechanism 104, as described above.

[0088] Referring to Figures 1 and 2, 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. In this example, the cart 164 moving along the track 166 is configured to move the attachment 102 to the working position 258 (or pre-work position) so that the gripper 108 finds and engages with the matching mechanism 104, as described above.

[0089] In one example, the track 166 is positioned such that the Z coordinates of the mounting fixture 102 and, consequently, the matching mechanism 104 are fixed and remain constant as the cart 164 moves along the track 166 to the working position 258. In this example, the positioning step performed by the gripper 108 only requires determining the XY coordinates of the contact point between the gripper 108 and the matching mechanism 104.

[0090] Referring to Figures 1 and 2, in one example, the manufacturing system 168 includes a work cell 106 and an automated machine 128. The automated machine 128 is located within the work cell 106 and is 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 a matching mechanism 104. The matching mechanism 104 is fixed to the fixture 102. For example, the matching mechanism 104 is connected to the fixture 102.

[0091] The manufacturing system 168 also includes a gripper 108. The gripper 108 is configured to engage with a mapping mechanism 104. The manufacturing system 168 further includes a controller 110. The controller 110 communicates with the gripper 108 and the automatic machine 128. The controller 110 is configured to position the fixture 102 relative to the work cell 106 from the gripper position 114 of the gripper 108 engaged with the mapping mechanism 104. The controller 110 is also configured to map the automatic machine 128 to the fixture position 118 of the fixture 102.

[0092] Referring to Figures 1 and 7, in the example of the manufacturing system 168, the controller 110 is configured to determine the gripper position 114 of the gripper 108 in at least one dimension of the fixed coordinate system 112. The controller 110 is also configured to determine the mapping mechanism position 116 of the mapping mechanism 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 the fixture position 118 of the fixture 102 in at least one dimension of the fixed coordinate system 112 from the mapping mechanism position 116 of the mapping mechanism 104. The controller 110 is also configured to register a digital model 120 representing the fixture 102 and the mapping mechanism 104 at the mapping mechanism position 116 of the mapping mechanism 104, and to convert the model position 126 of the digital model 120 registered at the mapping mechanism position 116 to the fixture position 118 of the fixture 102.

[0093] Referring to Figure 1-3, in an example of the manufacturing system 168, the fixture 102 includes a mandrel 130 configured to support a composite laminate, and the automated machine 128 includes an automated fiber placement machine 132 configured to perform at least one composite layup or lamination process.

[0094] Referring to Figures 2 and 4, in an example of the manufacturing system 168, the gripper 108 is connected to an automatic machine 128, which is configured to move the gripper 108 relative to a reference frame 216 in at least one dimension of the fixed coordinate system 112. Referring to Figures 5 and 6, in one example the gripper 108 is configured to move independently of the automatic machine 128. Referring to Figure 2-6, in one example the gripper 108 is configured to move the fixture 102 inside the work envelope 140 of the work cell 106.

[0095] Referring to Figures 8A, 8B, 9A, and 9B, in the example of the manufacturing system 168, the matching mechanism 104 includes at least one interface indicator portion 146. The gripper 108 includes at least one contact indicator portion 148 configured to engage with at least one interface indicator portion 146.

[0096] Referring to Figure 1-6, in one example the manufacturing system 168 includes a vehicle 160. The vehicle 160 is configured to support a fixture 102 and to move the fixture 102 relative to the work cell 106.

[0097] Referring to Figures 1 and 2, in one example the manufacturing system 168 also includes a track 166. The track 166 runs through the work cell 106. In this example the vehicle 160 includes or takes the form of a cart 164 configured to move along the track 166.

[0098] Referring to Figure 10, in one example, the manufacturing system 168 includes a second work cell 172. The manufacturing system 168 also includes a second automated machine 174. The second automated machine 174 is located within the second work cell 172 and is configured to perform at least one manufacturing process on a workpiece 170.

[0099] The manufacturing system 168 further includes a second gripper 176. The second gripper 176 is configured to engage with a mapping mechanism 104. A controller 110 communicates with the second gripper 176 and the second automatic machine 174. The controller 110 is configured to position the fixture 102 relative to the second work cell 172 from the second gripper position 178 of the second gripper 176 engaged with the mapping mechanism 104. The controller 110 is further configured to map the second automatic machine 174 to the second fixture position 180 of the fixture 102. Once mapped, the second automatic machine 174 performs at least one manufacturing step on the workpiece 170.

[0100] In another example, with a rough reference to Figure 1 and especially Figures 11-13, the matching device 100 includes a mounting fixture 102. The mounting fixture 102 is movable relative to the work cell 106. The opening 100 also includes a matching mechanism 104. The matching mechanism 104 is fixed relative to the mounting fixture 102. For example, the matching mechanism 104 is positioned on the mounting fixture 102.

[0101] In the example shown in Figure 11-15, the mounting mechanism 104 is connected to or positioned on the top of the mounting fixture 102. In another example, the mounting mechanism 104 is connected to or positioned on another part of the mounting fixture 102 (e.g., side, front, rear, bottom, etc.).

[0102] In one example, the mapping device 100 includes a sensor 184. The sensor 184 is configured to detect (e.g., visually identify) the mapping mechanism 104. The mapping mechanism 104 is appropriately positioned relative to the mounting fixture 102 such that at least a portion of it is visually accessible by the sensor 184. Conversely, the sensor 184 is appropriately positioned relative to the mounting fixture 102 such that at least a portion of it is physically accessible by the mapping mechanism 104. In one example, the mapping mechanism 104 is located on or formed within the exposed outer surface of the mounting fixture 102. The sensor 184 is configured to generate sensor data 186 (Figure 1) representing the position of the mapping mechanism 104 (mapping mechanism position 116) (Figure 1). In other words, the sensor 184 positions the mapping mechanism 104 within the reference frame 216.

[0103] Referring to Figure 11-13, in one example, the sensor 184 includes a joint mechanism 230 and a sensor head 242 connected to the working end of the joint mechanism 230. The joint 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 rotating about at least one axis of the fixed coordinate system 112.

[0104] The joint mechanism 230 is also configured to provide position data (e.g., interface data 222) (Figure 1) representing the position of the sensor 184 (e.g., sensor head 242) relative to the reference frame 216. In one example, the position data and sensor data 186 are used to determine the mapping mechanism position 116 relative to the reference frame 216. In one example, and for the purposes of this specification, the position data of the sensor 184 relative to the reference frame 216 is incorporated together with the sensor data 186.

[0105] Referring to Figure 13, the sensor head 242 includes or takes the form of one of various machine vision or computer vision systems configured to scan the mounting fixture 102 and identify the mapping mechanism 104 from the scan. In one example, the sensor 184 (e.g., sensor head 242) includes or takes the form of a camera configured to capture still images or videos (e.g., sensor data 186) that visually represent the mounting fixture 102 and the mapping mechanism 104. In another example, the sensor 184 (e.g., sensor head 242) includes or takes the form of a laser scanner configured to project laser light onto the mounting fixture 102, collect the laser light polarized backward from the mounting fixture 102, and generate sensor data 186 from the collected laser light representing the mapping mechanism 104.

[0106] In one example, sensor data 186 represents or corresponds to the position 116 of the mapping mechanism. In another example, the laser scanner is a two-dimensional laser scanner, and sensor data 186 represents the position of the mapping mechanism 104 in two dimensions (e.g., XY coordinates) of a fixed coordinate system. In yet another example, the laser scanner is a three-dimensional scanner, and sensor data 186 represents the position of the mapping mechanism in three dimensions (e.g., XYZ coordinates) of a fixed coordinate system.

[0107] Referring to Figures 11 and 12, in one example, the joint mechanism 230 is connected to or forms part of the automated machine 128. In Figure 12, the robotic arm 226 and end effector 228 (Figure 11) of the automated machine 128 (for example, to perform at least one manufacturing process) have been removed for clarity. In this example, the automated machine 128 is configured to move the sensor 184 relative to the work cell 106 and the fixture 102 in at least one dimension of the fixed coordinate system 112. In other words, at least a portion of the range of motion of the joint mechanism 230, i.e., one or more degrees of freedom, is provided by the automated machine 128.

[0108] Referring to Figure 13, in one example, the joint mechanism 230 is separate from and independent of the automatic machine 128. In this example, the entire range of motion of the sensor 184, i.e., all degrees of freedom, is provided by the joint mechanism 230 (for example, those specific to the joint mechanism 230).

[0109] Referring to Figure 14, in another example of the mapping device 100, the interface device 220 (Figure 1) includes two or more sensors 184 (hereinafter referred to as multiple sensors 184). In this example, the mapping device 100 includes two or more mapping mechanisms 104 (e.g., multiple mapping mechanisms 104). Each of the mapping mechanisms 104 is fixed to a mounting fixture 102. Each of the sensors 184 is configured to scan, detect, and position at least a portion of the mapping mechanism 104, or a corresponding one of the multiple mapping mechanisms 104.

[0110] Referring to Figures 1 and 11-15, the mapping device 100 also includes a controller 110. The controller 110 communicates with the sensor 184. The controller 110 is configured to position the fixture 102 relative to the work cell 106 from the mapping mechanism position 116 of the mapping mechanism 104, which is identified by the sensor 184.

[0111] In one example, the controller 110 is configured to determine the position 116 of the mapping mechanism 104 relative to the reference frame 216 in at least one dimension of the fixed coordinate system 112, for example, from the sensor data 186 generated by the sensor 184. The controller 110 is also configured to determine the position 118 of the mounting fixture 102 relative to the reference frame 216 in at least one dimension of the fixed coordinate system 112, for example, from the position 116 of the mapping mechanism 104.

[0112] In one example, the controller 110 is configured to register a digital model 120 (Figure 1) representing the mounting fixture 102 and the mapping mechanism 104 at the mapping mechanism position 116 of the mapping mechanism 104. The controller 110 is also configured to convert the model position 126 of the digital model 120 registered at the mapping mechanism position 116 to the mounting fixture position 118 of the mounting fixture 102.

[0113] Figure 16 schematically shows an example of an input 234 provided to the controller 110 during the positioning and mapping process, and an output 236 generated by the controller 110. In one example, sensor data 186 is provided to the controller 110 from sensor 184. Sensor data 186 is an example of interface data 222 (Figure 1). In one example, sensor data 186 (e.g., interface data 222) also includes position data representing the actual physical position of sensor 184 (e.g., sensor head 242) (Figure 13) relative to a reference frame 216, such as being generated by an encoder, sensor, other relative positioning device, or a combination thereof. The controller 110 processes the sensor data 186 and determines the mapping mechanism position 116 based on the sensor data 186.

[0114] Referring to Figure 11-15, in one example, the sensor 184 (e.g., sensor head 242) moves along the scanframe relative to the mounting fixture 102, scanning at least a portion of the mounting fixture 102, including the mapping mechanism 104. The sensor 184 may position the mapping mechanism 104 in a single pass or it may require two or more passes to collect a sufficient number of data points of sensor data 186 (Figure 16). The controller 110 is configured to identify and extract the data points representing the mapping mechanism 104. The controller 110 then determines the XYZ coordinates of the data points representing the mapping mechanism 104 relative to the reference frame 216. The controller 110 then determines the mapping mechanism position 116, which is described by the XYZ coordinates of the data points representing the mapping mechanism 104 in the sensor data 186.

[0115] The mapping mechanism 104 includes a structure that is visually perceptible and / or computer-distinguishable from the surface area surrounding the mounting fixture 102. For example, the mapping mechanism 104 includes a structural configuration suitable for computer perception and recognition, such as in a point cloud processing step performed on multiple data points of sensor data 186. The mapping mechanism position 116 is described by the XYZ coordinates of multiple data points representing the mapping mechanism 104 in the sensor data 186.

[0116] It should be noted that increasing the number of data points representing the mapping mechanism 104 within the sensor data 186 will yield more XYZ coordinate data points for processing, and as a result, the accuracy of the mapping mechanism position 116 and the mounting fixture position 118 during data point alignment in the mapping process will improve.

[0117] The controller 110 is configured to register a digital model 120 representing the mounting fixture 102 and the mapping mechanism 104 at the mapping mechanism position 116 and to determine the model position 126. In one example, the controller 110 is configured to align the digital model 120 with the XYZ coordinates describing the mapping mechanism position 116 within the reference frame 216. The digital model 120 includes data points representing the mapping mechanism 104. In one example, the controller 110 performs a best-fit process (for example, by performing a best-fit algorithm) to align the data points representing the mapping mechanism 104 with the data points representing the XYZ coordinates describing the mapping mechanism position 116. In one example, the best-fit process includes a rigid body point cloud transformation process.

[0118] Once the digital model 120 is registered and aligned with the corresponding mechanism position 116, the controller 110 is configured to convert the model position 126 to, for example, the fixture position 118 of the fixture 102 relative to the reference frame 216. For example, the fixture position 118 is assumed to be the same as the model position 126 within tolerance. Therefore, the fixture position 118 represents the most recent (e.g., current, real-time) position of the fixture 102, and consequently the workpiece 170, relative to the work cell 106 and the automatic machine 128.

[0119] If the fixture position 118 is known, the automated machine 128 is associated with or "set to zero" the fixture position 118 and performs the manufacturing process on the workpiece 170 according to a predetermined toolpath. Based on the fixture position 118, the automated machine 128 is associated with the fixture 102, and consequently, the automated machine 128 is associated with 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 described in the programmed toolpath of the automated machine 128.

[0120] Referring to Figures 1 and 11, in one example the mapping device 100 includes an automatic machine 128. The automatic machine 128 is located in the work cell 106 and communicates with the controller 110. The controller 110 is configured to map the automatic machine 128 to the mounting position 118 of the mounting fixture 102.

[0121] Referring to Figures 11, 12, 14, and 15, in one example the automated machine 128 includes a gantry 134. In this example, the fixture 102, and by extension the workpiece 170, is moved to a working position 258 within the work cell 106, and the gantry 134 and / or the robot arm 226 connected to the gantry 134 move relative to the fixture 102 so that the end effector 228 follows a predetermined toolpath.

[0122] In another example (not shown), the robot arm 226 is a standalone robot with a fixed base within the work cell 106. In this example, the fixture 102, and thus the workpiece 170, is moved to a working position 258 within the work cell 106, and the robot arm 226 moves relative to the fixture 102 so that the end effector 228 follows a predetermined toolpath.

[0123] The illustrated example of the matching device 100 shows only one automated machine 128 (e.g., one robotic arm 226 with one end effector 228) for performing the manufacturing process on the workpiece 170 in the work cell 106, but in other examples the matching device 100 may have any number of additional automated machines 128 (e.g., additional robotic arms 226 and / or additional end effectors 228).

[0124] Referring to Figures 1 and 11, in one example the manufacturing process includes a composite layup process and / or a composite lamination process. Before curingThe process includes a composite assembly step. In this example, the workpiece 170 includes a composite laminate (e.g., a composite material layup). The fixture 102 includes or takes the form of a mandrel 130. The mandrel 130 is configured to support the composite laminate. The automated machine 128 includes or takes the form of an automated fiber placement machine 132.

[0125] In one example, the fixture 102 is moved to the working position 258, and the nearest position of the fixture 102 to the workpiece 170 (e.g., the fixture position 118) is determined using the sensor 184 and the matching 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 automatic fiber placement machine 132 laps and / or compacts at least a portion of at least one layer of the composite sheet stack.

[0126] In one or more other examples (not explicitly shown), the manufacturing process includes another assembly or machining process. In such examples, the workpiece 170 is After curing The workpiece may be a composite workpiece, a metal workpiece, a plastic workpiece, or other non-composite workpiece. The fixture 102 includes a suitable holding mechanism 260 (Figure 1) configured to secure the workpiece 170 during transfer to the work cell 106 and during the manufacturing process. The automated machine 128 includes or takes the form of any suitable machine tool.

[0127] Referring to Figures 12, 14, and 15, in one example the mapping device 100 includes a drive assembly 138 connected to the sensor 184. The drive assembly 138 is configured to move the sensor 184 (e.g., sensor head 242) relative to the reference frame 216 in one or more dimensions of a fixed coordinate system 112, for example. In one example, the drive assembly 138 is connected to or forms part of the joint mechanism 230 of the sensor 184, such as in an example where the sensor 184 is separate from the automatic machine 128, as shown in Figures 14 and 15. In another example, the drive assembly 138 is connected to or formed by the automatic machine 128, such as in an example where the sensor 184 is connected to the automatic machine 128, as shown in Figures 11 and 12.

[0128] In one example, the matching device 100 includes an independent moving mechanism (not shown) configured to move the mounting fixture 102 to the working position 258.

[0129] Referring to Figure 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.

[0130] In one example, the interface structure 192 is positioned on the surface 194 (e.g., exposed surface) of the fixture 102. In other words, the interface structure 192 is positioned appropriately so as not to be covered or otherwise hidden by the workpiece 170 (not shown in Figure 13) fixed to the fixture 102. The interface structure 192 is positioned appropriately so as to be visually accessible by the sensor 184 during the positioning and mapping process described above. The interface structure 192 includes any one of a variety of different structures that are visually perceptible and / or computer-distinguishable from the surface 194 of the fixture 10 surrounding the mapping mechanism 104. Figure 17-20 schematically shows various examples of the interface structure 192.

[0131] Referring to Figure 17, in one example of the correspondence mechanism 104, the interface structure 192 is continuous and extends longitudinally along the surface 194 (e.g., top surface) of the mounting 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 Figure 17. In another example, the interface structure 192 may be non-linear.

[0132] Referring to Figure 18, in another example of the correspondence 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 (for example, also referred to herein as a plurality of interface structures 192). In one example, the plurality of interface structures 192 may be arranged linearly, as shown in Figure 18. In another example, the plurality of interface structures 192 may be arranged nonlinearly.

[0133] In one example, the interface structure 192 is a continuous groove formed (e.g., arising from) the surface 194 of the fixture 102. In another example, the interface structure 192 is a continuous ridge formed (e.g., protruding from) the surface 194 of the fixture 102. In yet another example, each of the multiple interface structures 192 includes an opening formed (e.g., arising from) the surface 194. In yet another example, each of the multiple interface structures 192 includes a projection formed (e.g., protruding from) the surface 194.

[0134] 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 possible.

[0135] Referring to Figure 19, in another example, the interface structure 192 is formed by the edge of the fixture 102. In one example, this edge extends continuously and longitudinally along the fixture 102. In one example, this edge is formed by the intersection of two exposed surfaces 194 (e.g., top and side) of the fixture 102. In the illustrated example, the interface structure 192 of the correspondence mechanism 104 includes or is formed by two edges of the fixture 102. In other examples, the interface structure 192 of the correspondence mechanism 104 includes or is formed by any number of edges.

[0136] In another example, the interface structure 192 includes a combination of two or more structural elements, such as grooves, ridges, a series of openings, a series of protrusions, and edges. Various other configurations of the interface structure 192 are also possible.

[0137] In an example where the mapping 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 each other (e.g., oriented at an angle to each other). The non-parallel arrangement of the interface structures 192 provides non-parallel data points in the sensor data 186 that can be combined during processing, allowing for the derivation of the XYZ coordinates of multiple data points relative to the reference frame 216 in one or more dimensions of the fixed coordinate system 112.

[0138] Referring to Figure 11-15, in one example, the alignment device 100 includes a vehicle 160. The vehicle 160 supports a mounting fixture 102 and is configured to move the mounting fixture 102 relative to the work cell 106. In one example, the vehicle 160 is configured to move the mounting fixture 102, and thus the workpiece 170, to a work position 258 detected (e.g., visually identified) by a sensor 184 scanning the alignment mechanism 104, thereby performing the positioning and alignment process described above.

[0139] Referring to Figure 1, in an example of the matching device 100, the vehicle 160 includes or takes the form of an automated guidance vehicle 162. Referring to Figures 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 that passes through the work cell 106.

[0140] In one example, the track 166 is positioned such that the Z coordinates of the mounting fixture 102 and, consequently, the matching mechanism 104 are fixed and remain constant as the cart 164 moves along the track 166 to the work position 258. In this example, the positioning process performed by the sensor 184 only requires determining the XY coordinates of the matching mechanism 104.

[0141] Referring to Figures 1 and 11, in another example, the manufacturing system 168 includes a work cell 106 and an automated machine 128. The automated machine 128 is located within the work cell 106 and is configured to perform at least one manufacturing step. 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 a matching mechanism 104. The matching mechanism 104 is fixed to the fixture 102. For example, the matching mechanism 104 is located on the fixture 102.

[0142] The manufacturing system 168 also includes a sensor 184. The sensor 184 is configured to detect (e.g., visually identify) the mapping mechanism 104. The manufacturing system 168 further includes a controller 110 that communicates 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 the mapping mechanism position 116 of the mapping mechanism 104, which is identified by the sensor 184. The controller 110 is also configured to associate the automated machine 128 with the fixture position 118 of the fixture 102.

[0143] Referring to Figures 1 and 16, in the example of the manufacturing system 168, the controller 110 is configured to determine the mapping mechanism position 116 of the mapping mechanism 104 in at least one dimension of the fixed coordinate system 112 from sensor data 186 generated by the sensor 184. The controller 110 is also configured to determine the fixture position 118 of the fixture 102 in at least one dimension of the fixed coordinate system 112 from the mapping mechanism position 116 of the mapping mechanism 104. The controller 110 is further configured to register a digital model 120 representing the fixture 102 and the mapping mechanism 104 at the mapping mechanism position 116 of the mapping mechanism 104, and to convert the model position 126 of the digital model 120 registered at the mapping mechanism position 116 to the fixture position 118 of the fixture 102.

[0144] Referring to Figures 1, 11 and 13, in an example of the manufacturing system 168, the fixture 102 includes a mandrel 130 configured to support a composite laminate, and the automated machine 128 includes an automated fiber placement machine 132 configured to perform at least one composite layup or lamination process.

[0145] Referring to Figures 11 and 12, in an example of the manufacturing system 168, the sensor 184 is connected to an automated machine 128, which is configured to move the sensor 184 relative to the mounting fixture 102 in at least one dimension of the fixed coordinate system 112. Referring to Figures 14 and 15, in one example, the sensor 184 is configured to move independently of the automated machine 128.

[0146] Referring to Figures 13 and 17-19, in the example of the manufacturing system 168, the matching mechanism 104 includes at least one interface structure 192 located on the surface 194 of the fixture 102. The interface structure 192 is visually detectable (e.g., perceptible and recognizable) by the sensor 184.

[0147] Referring to Figures 1 and 11-15, in one example, the manufacturing system 168 includes a vehicle 160. The vehicle 160 is configured to support a fixture 102 and to move the fixture 102 relative to a work cell 106.

[0148] Referring to Figures 1 and 11, in one example the manufacturing system 168 also includes a track 166. The track 166 runs through the work cell 106. In this example the vehicle 160 includes or takes the form of a cart 164 configured to move along the track 166.

[0149] Referring to Figure 20, in one example, the manufacturing system 168 includes a second work cell 172. The manufacturing system 168 also includes a second automated machine 174. The second automated machine 174 is located within the second work cell 172 and is configured to perform at least one manufacturing process on a workpiece 170.

[0150] The manufacturing system 168 also includes a second sensor 198. The second sensor 198 is configured to detect (e.g., visually identify) the mapping mechanism 104. The controller 110 communicates with the second sensor 198 and the second automatic machine 174. The controller 110 is configured to position the fixture 102 relative to the second work cell 172 from the second mapping mechanism position 200 of the mapping mechanism 104, which is identified by the second sensor 198. The controller 110 is also configured to associate the second automatic machine 174 with the second fixture position 180 of the fixture 102. Once associated, the second automatic machine 174 performs at least one manufacturing step on the workpiece 170.

[0151] In another example, with a rough reference to Figure 1 and especially Figures 21-23, the mapping device 100 includes a mounting fixture 102. The mounting fixture 102 is movable relative to the work cell 106. The mapping device 100 also includes a mapping mechanism 104. The mapping mechanism 104 is fixed to the mounting fixture 102. For example, the mapping mechanism 104 is formed by the mounting fixture 102 or otherwise positioned on it.

[0152] In the example shown in Figure 21-23, the matching mechanism 104 is connected to or positioned on at least one side of the mounting fixture 102. In other examples, the matching mechanism 104 is connected to or positioned on another part of the mounting fixture 102 (e.g., an opposing side, front, rear, top, bottom, etc.).

[0153] In one example, the mapping device 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 with (for example, to be in physical contact with) the mapping mechanism 104. The mapping mechanism 104 is appropriately positioned relative to the fixture 102 such that at least a portion of the mapping mechanism 104 is physically accessible by the plurality of probes 202. Conversely, the plurality of probes 202 are appropriately positioned relative to the fixture 102 such that at least a portion of the plurality of probes 202 is physically accessible by the mapping mechanism 104. With the plurality of probes 202 engaged with the mapping mechanism 104, the plurality of positions of the plurality of probes 202 (also referred to herein as the plurality of probe positions 204) (Figure 1) represent or correspond to the mapping mechanism position 116 (Figure 1). In other words, the plurality of probes 202 position the mapping mechanism 104 within the reference frame 216.

[0154] Referring to Figure 21-23, in an example of the mapping device 100, the multiple probes 202 form part of a probe assembly 250 (for example, the probe assembly 250 includes the multiple probes 202). The probe assembly 250 includes a drive mechanism 252 connected to each of the multiple probes associated with the probe assembly 250. The drive mechanism 252 is configured to move each of the multiple probes 202 (for example, collectively called probes 202, or individually called 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., stretch or retract) each probe 202 in one dimension of the fixed coordinate system 112 (e.g., the Y direction).

[0155] The drive mechanism 252 includes at least one suitable drive motor (not shown) for driving the movement of the probe 202, such as an electromechanical motor, a pneumatic motor, or a hydraulic motor. The probe assembly 250 is also configured to provide position data (e.g., interface data 222) representing multiple positions of the probe 202 relative to a reference frame 216, for example, in at least one dimension of the fixed coordinate system 112. 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 a controller 110.

[0156] In the examples illustrated in Figures 21 and 22, the mapping device 100 includes, for example, two probe assemblies 250 facing each other, such that the probes 202 associated with each probe assembly 250 engage with corresponding mapping mechanisms 104 located, for example, on opposite sides of the mounting fixture 102. In another example, the mapping device 100 includes one probe assembly 250 such that the probes 202 associated with the probe assembly 250 engage with mapping mechanisms 104 located on the mounting fixture 102.

[0157] Referring to Figures 1 and 21-23, the mapping device 100 also includes a controller 110. The controller 110 communicates with a 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, while the plurality of probes 202 are engaged with the mapping mechanism 104.

[0158] In the example of the mapping device 100, the controller 110 is configured to determine multiple probe positions 204 of multiple probes 202 relative to a reference frame 216 in at least one dimension of the fixed coordinate system 112. The controller 110 is also configured to determine the mapping mechanism position 116 of the mapping mechanism 104 relative to the reference frame 216 in at least one dimension of the fixed coordinate system 112 from the multiple probe positions 204 of the multiple probes 202. The controller 110 is further configured to determine the mounting fixture position 118 of the mounting fixture 102 relative to the reference frame 216 in at least one dimension of the fixed coordinate system 112 from the mapping mechanism position 116 of the mapping mechanism 104.

[0159] In one example, the controller 110 is configured to register a digital model 120 (Figure 1) representing the mounting fixture 102 and the mapping mechanism 104 at the mapping mechanism position 116 of the mapping mechanism 104. The controller 110 is also configured to convert the model position 126 of the digital model 120 registered at the mapping mechanism position 116 to the mounting fixture position 118 of the mounting fixture 102.

[0160] Figure 24 schematically shows an example of an input 234 provided to the controller 110 during the positioning and mapping process, and an output 236 generated by the controller 110. In one example, probe position data 254 is provided to the controller 110 by the probe assembly 250. Probe position data 254 is an example of interface data 222 (Figure 1). In one example, probe position data 254 is generated by an encoder, sensor, other relative position information device, or a combination thereof, and represents the actual physical positions (probe positions 204) of multiple probes 202 (Figure 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 mapping mechanism position 116 based on the probe positions 204.

[0161] Referring to Figures 21-23, in one example, when the probe 202 is engaged with the mapping mechanism 104, there are multiple contact points between the probe 202 and the mapping mechanism 104. Each of these contact points has a common XYZ coordinate for both the corresponding probe 202 and the mapping mechanism 104. The probe position data 254 (Figure 24) represents the XYZ coordinates of the contact points of the probe 202 (e.g., the XYZ coordinates of the contact points of each probe 202), and the probe position 204 is described by the XYZ coordinates of the contact points of the probe 202. The controller 110 converts the XYZ coordinates of the contact points of the probe 202 to the XYZ coordinates of the corresponding contact points of the mapping mechanism 104. The controller 110 then determines the mapping mechanism position 116, which is described by the XYZ coordinates of the contact points of the mapping mechanism 104.

[0162] In one example, the probe assembly 250 includes at least two probes 202 corresponding to at least two contact points between the probe 202 and the mapping mechanism 104, and as a result provides at least two XYZ coordinates describing the mapping mechanism position 116 of the mapping mechanism 104. In another example, the probe assembly 250 includes at least three probes 202 corresponding to at least three contact points between the probe 202 and the mapping mechanism 104, and as a result provides at least three XYZ coordinates describing the mapping mechanism position 116 of the mapping mechanism 104. In yet another example, a combination of probes 202 from two or more probe assemblies 250 corresponds to at least three contact points between the probe 202 and the mapping mechanism 104, and as a result provides at least three XYZ coordinates describing the mapping mechanism position 116 of the mapping mechanism 104.

[0163] In one example, multiple contact points are provided by a probe 202 of one probe assembly 250 that engages with a mapping mechanism 104 located on the fixture 102. In another example, some contact points are provided by a probe 202 associated with a first probe assembly 250 that engages with a first portion of the mapping mechanism 104 (or first mapping mechanism 104) located on a first side (or first surface) of the fixture 102, and some contact points are provided by a probe 202 associated with a second probe assembly 250 that engages with a second portion of the mapping mechanism 104 (or second mapping mechanism 104) located on a second side (or second surface) of the fixture 102.

[0164] It should be noted that increasing the number of contact points between the probe 202 and the mapping mechanism 104 (for example, by increasing the number of probes 202 that engage with the mapping mechanism 104) will result in a greater number of XYZ coordinate data points for processing, thereby improving the accuracy of the mapping mechanism position 116 and the mounting fixture position 118 during the alignment of data points in the mapping process.

[0165] In the illustrated example, the probe 202 (for example, of an opposing probe assembly 250) is positioned to engage with a portion of a mapping mechanism 104 (or a number of different mapping mechanisms 104) located on opposing sides (e.g., both sides) of the fixture 102. In other examples (not shown), the probe 202 (for example, of an additional or alternative probe assembly 250) is positioned to engage with a portion of a mapping mechanism 104 (or a number of different mapping mechanisms 104) located on another portion or surface (e.g., top, bottom, front, back) of the fixture 102.

[0166] Referring to Figure 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 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.

[0167] The controller 110 converts the XYZ coordinates of the contact point of the contact indicator unit 148 to the XYZ coordinates of the corresponding contact point of the interface indicator unit 146. The controller 110 determines the corresponding mechanism position 116, which is described by the XYZ coordinates of the contact point of the interface indicator unit 146.

[0168] Generally, multiple probes 202 include or form multiple contact indicators 148, and the mapping mechanism 104 includes or forms multiple interface indicators 146, thereby providing multiple contact points. Therefore, the probe position data 254 (Figure 24) represents the XYZ coordinates of the multiple contact points of the contact indicators 148 of the probes 202. The multiple probe positions 204 are described by the XYZ coordinates of the contact points of the contact indicators 148 of the multiple probes 202. The mapping mechanism positions 116 are described by the XYZ coordinates of the corresponding multiple contact points of the interface indicators 146.

[0169] 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 mapping mechanism 104, resulting in a greater number of XYZ coordinate data points for processing, thereby improving the accuracy of the mapping mechanism position 116 and the fixture position 118 during the alignment of data points in the mapping process. In one example, the probe assembly 250 (e.g., multiple probe assemblies 202) includes at least three contact indicators 148, and the mapping mechanism 104 includes at least three interface indicators 146.

[0170] Referring again to Figure 24, the controller 110 is configured to register a digital model 120 representing the mounting fixture 102 and the mapping mechanism 104 at the mapping mechanism position 116 and to determine the model position 126. In one example, the controller 110 is configured to align the digital model 120 with the XYZ coordinates describing the mapping mechanism position 116 within the reference frame 216. The digital model 120 includes data points representing the contact points of the mapping mechanism 104. For example, the digital model 120 includes data points representing the interface index portion 146 of the mapping mechanism 104. In one example, the controller 110 performs a best-fit process (for example, the best-fit algorithm is executed) to align the data points representing the contacts of the mapping mechanism 104, for example, the data points representing the interface index portion 146, with the data points representing the XYZ coordinates describing the mapping mechanism position 116. In one example, the best-fit process includes a rigid body point cloud transformation process.

[0171] Once the digital model 120 is registered and aligned with the corresponding mechanism position 116, the controller 110 is configured to convert the model position 126 to the fixture position 118 of the fixture 102 relative to the reference frame 216. For example, the fixture position 118 is assumed to be the same as the model position 126 within tolerance. Thus, the fixture position 118 represents the most recent (e.g., current, real-time) position of the fixture 102, and by extension the workpiece 170, relative to the work cell 106 and the automated machine 128.

[0172] If the fixture position 118 is known, the automated machine 128 is associated with or "set to zero" the fixture position 118 and performs the manufacturing process on the workpiece 170 according to a predetermined toolpath. Based on the fixture position 118, the automated machine 128 is associated with the fixture 102, and consequently, the automated machine 128 is associated with 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 described in the programmed toolpath of the automated machine 128.

[0173] Referring to Figures 1 and 21, in one example, the mapping device 100 includes an automatic machine 128. The automatic machine 128 is located within the work cell 106. The automatic machine 128 communicates with a controller 110. The controller 110 is configured to map the automatic machine 128 to the mounting position 118 of the mounting fixture 102.

[0174] Referring to Figures 22 and 23, in one example the automated machine 128 includes a gantry 134. In this example, the fixture 102, and by extension the workpiece 170, is moved to a working position 258 within the work cell 106, and the gantry 134 and / or the robot arm 226 connected to the gantry 134 move relative to the fixture 102 so that the end effector 228 follows a predetermined toolpath.

[0175] In another example (not shown), the robot arm 226 is a standalone robot with a fixed base within the work cell 106. In this example, the fixture 102, and thus the workpiece 170, is moved to a working position 258 within the work cell 106, and the robot arm 226 moves relative to the fixture 102 so that the end effector 228 follows a predetermined toolpath.

[0176] The illustrated example of the matching device 100 shows only one automated machine 128 (e.g., one robotic arm 226 with one end effector 228) to perform the manufacturing process on the workpiece 170 in the work cell 106, but in other examples the matching device 100 may have any number of additional automated machines 128 (e.g., additional robotic arms 226 and / or additional end effectors 228).

[0177] Referring to Figures 1 and 22, in one example the manufacturing process includes a composite layup process and / or a composite lamination process. Before curingThe process includes a composite assembly step. In this example, the workpiece 170 includes a composite laminate (e.g., a composite material layup). The fixture 102 includes or takes the form of a mandrel 130. The mandrel 130 is configured to support the composite laminate. The automated machine 128 includes or takes the form of an automated fiber placement machine 132.

[0178] In one example, the fixture 102 is moved to the working position 258, and the nearest position of the fixture 102 to the workpiece 170 (e.g., the fixture position 118) is determined using multiple probes 202 and the matching 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 automatic fiber placement machine 132 laps and / or compacts at least a portion of at least one layer of the composite sheet stack.

[0179] In one or more other examples (not explicitly shown), the manufacturing process includes another assembly or machining process. In such examples, the workpiece 170 is After curing The workpiece may be a composite workpiece, a metal workpiece, a plastic workpiece, or other non-composite workpiece. The fixture 102 includes a suitable holding mechanism 260 (Figure 1) configured to secure the workpiece 170 during transfer to the work cell 106 and during the manufacturing process. The automated machine 128 includes or takes the form of any suitable machine tool.

[0180] In one example, the matching device 100 includes an independent moving mechanism (not shown) configured to move the mounting fixture 102 to the working position 258.

[0181] Figures 25 and 26 schematically illustrate examples of the mapping mechanism 104. Figure 27 schematically illustrates an example of a probe 202 and the mapping mechanism 104. Generally, the mapping mechanism 104 includes at least one interface indicator portion 146. In one example, the interface indicator portion 146 is located on (e.g., positioned or formed on) the surface 194 of the fixture 102. Each of the plurality of probes 202 includes a contact indicator portion 148 (Figure 27). The contact indicator portion 148 is movable relative to at least one interface indicator portion 146. The contact indicator portion 148 is configured to engage with the interface indicator portion 146 so that the probe 202 can position the mapping mechanism 104.

[0182] Referring to Figure 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 matching mechanism 104. In one example, each probe 202 includes a probe shaft 256. The probe head 208 is connected to the end of the probe shaft 256. The drive mechanism 252 is configured to extend and retract the probe shaft 256 to move the probe head 208.

[0183] In one example, the interface indicator portion 146 includes or is formed by at least one interface structure 206 located on the surface 194 of the mounting fixture 102. For example, the interface indicator portion 146 is formed by a portion of the interface structure 206, for example, a portion of the surface of the interface structure 206. In one example, the contact indicator portion 148 includes or is formed by a probe head 208. In this example, the probe head 208 is the contact structure of the contact indicator portion 148. For example, the contact indicator portion 148 is formed by a portion of the probe head 208, for example, a portion of the surface of the probe head 208.

[0184] In one example, the probe head 208 is configured to engage with the interface structure 206, so that the contact indicator 148 contacts the interface indicator 146. The contact indicator 148 and the interface indicator 146 are configured to contact and interlock with each other when the probe 202 (e.g., the probe head 208) properly engages with the matching mechanism 104 (e.g., the interface structure 206).

[0185] Referring to Figure 25, in one example of the correspondence mechanism 104, the interface structure 206 is continuous and extends longitudinally along the surface 194 (e.g., side) of the mounting 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 Figure 25. In another example, the interface structure 206 may be non-linear.

[0186] Referring to Figure 26, in another example of the correspondence 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 (for example, also referred to herein as a plurality of interface structures 206). In one example, the plurality of interface structures 206 may be arranged nonlinearly. In another example, the plurality of interface structures 206 may be arranged nonlinearly as shown in Figure 26.

[0187] In one example, the probe head 208 and the interface structure 206 have complementary geometric shapes and dimensions, so that corresponding surfaces of the probe head 208 (e.g., forming the contact indicator portion 148) and the interface structure 206 (e.g., forming the interface indicator portion 146) are in contact when the probe 202 properly engages with the matching mechanism 104. Each of the probe head 208 and the interface structure 206 includes or takes the form of one of a variety of structural configurations.

[0188] In one example, the interface structure 206 is a continuous groove formed (e.g., arising from) the surface 194 of the fixture 102. In this example, the probe head 208 is configured to be inserted into a portion of the interface structure 206. In another example, the interface structure 206 is a continuous ridge formed (e.g., protruding from) the surface 194 of the fixture 102. In this example, the probe head 208 is configured to receive a portion of the interface structure 206. In yet another example, each of the multiple interface structures 206 includes an opening formed (e.g., arising from) the surface 194. In this example, the probe head 208 is configured to be inserted into the interface structure 206. In yet another example, each of the multiple interface structures 206 includes a projection formed (e.g., protruding from) the surface 194. In this example, the probe head 208 is configured to receive the interface structure 206.

[0189] Other structural configurations and / or arrangements of the contact indicator section 148 (e.g., probe head 208) and the interface indicator section 146 (e.g., interface structure 206) are also possible.

[0190] In another example of the mapping mechanism 104, the interface structure 206 includes or takes the form of at least one surface 194 (e.g., outer surface) of the fixture 102. In other words, the surface 194 of the fixture 102 is configured such that each of the multiple probes 202, which are the interface structure 206 of the interface indicator portion 146, moves its probe head 208 to contact the surface 194 of the fixture 102. For example, the drive mechanism 252 extends the probe shaft 256 to move the probe head 208 to contact the surface 194, thereby positioning the contact indicator portion 148, formed by a portion of the surface of the probe head 208, to contact the interface indicator portion 146, formed by a portion of the surface 194 of the fixture 102.

[0191] Referring to Figure 27, in an example of the mapping device 100, the probe assembly 250 includes a displacement sensor 210. The displacement sensor 210 communicates with each of the multiple probes 202. The displacement sensor 210 is configured to measure the displacement of each of the multiple probes 202 (e.g., each of the probes 202) in at least one dimension of the fixed coordinate system 112 when the multiple probes 202 move and come into contact with the mapping mechanism 104. In one example, the displacement sensor 210 generates displacement data that represents the displacement or movement of the probes 202 and corresponds to the probe position 204. This displacement data is an example of probe position data 254 (Figure 24) provided to the controller 110.

[0192] Referring to Figure 21-23, in one example, the alignment device 100 includes a vehicle 160. The vehicle 160 supports a mounting fixture 102 and is configured to move the mounting fixture 102 relative to the work cell 106. In one example, the vehicle 160 is configured to perform the positioning and alignment process by moving the mounting fixture 102, and by extension the workpiece 170, to a work position 258 where a plurality of probes 202 extend so as to engage with the alignment mechanism 104.

[0193] Referring to Figure 1, in an example of the mapping device 100, the vehicle 160 includes or takes the form of an automated guidance vehicle 162. Referring to Figures 1 and 22, in an example of the mapping device 100, the vehicle 160 includes or takes the form of a cart 164. The cart 164 is configured to move along a track 166 that passes through the work cell 106.

[0194] In one example, the track 166 is positioned such that the Z coordinates of the mounting fixture 102, and consequently the matching mechanism 104, are fixed and remain constant as the cart 164 moves along the track 166 to the working position 258. In this example, the positioning process performed by multiple probes 202 only requires determining the XY coordinates of the matching mechanism 104.

[0195] Referring to Figures 1 and 21, in another example, the manufacturing system 168 includes a work cell 106 and an automated machine 128. The automated machine 128 is located within the work cell 106 and is configured to perform at least one manufacturing step. 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 a matching mechanism 104. The matching mechanism 104 is fixed to the fixture 102. For example, the matching mechanism 104 is located on the fixture 102.

[0196] 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 with a mapping mechanism 104. The manufacturing system 168 further includes a controller 110 that communicates 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 mapping mechanism 104. The controller 110 is also configured to map the automated machine 128 to a fixture position 118 of the fixture 102.

[0197] Referring to Figures 1 and 24, in the example of the manufacturing system 168, the controller 110 is configured to determine multiple probe positions 204 of multiple probes 202 relative to a reference frame 216 in at least one dimension of the fixed coordinate system 112. The controller 110 is also configured to determine the mapping mechanism position 116 of the mapping mechanism 104 relative to the reference frame 216 in at least one dimension of the fixed coordinate system 112 from the multiple probe positions 204 of the multiple probes 202. The controller 110 is further configured to determine the mounting fixture position 118 of the mounting fixture 102 relative to the reference frame 216 in at least one dimension of the fixed coordinate system 112 from the mapping mechanism position 116 of the mapping mechanism 104. The controller 110 is also configured to register a digital model 120 representing the mounting fixture 102 and the mapping mechanism 104 at the mapping mechanism position 116 of the mapping mechanism 104, and to convert the model position 126 of the digital model 120 registered at the mapping mechanism position 116 to the mounting fixture position 118 of the mounting fixture 102.

[0198] Referring to Figures 1 and 21, in an example of the manufacturing system 168, the fixture 102 includes or takes the form of a mandrel 130 configured to support the composite laminate, and the automated machine 128 includes or takes the form of an automated fiber placement machine 132.

[0199] Referring to Figures 21 and 21, in the example of the manufacturing system 168, the multiple probes 202 are configured to engage with the mapping mechanism 104 while the fixture 102 is inside the work envelope 140 of the work cell 106. In the example of the manufacturing system 168, the mapping mechanism 104 includes or takes the form of at least one surface 194 of the fixture 102. Each of the multiple probes 202 moves along at least one dimension of the fixed coordinate system 112 to contact at least one surface 194.

[0200] Referring to Figures 23 and 25-27, in an example of the manufacturing system 168, the matching mechanism 104 includes at least one interface indicator portion 146 located on the surface 194 of the fixture 102. Each of the plurality of probes 202 includes a contact indicator portion 148 that is movable with respect to at least one interface indicator portion 146 and configured to engage with at least one interface indicator portion 146. In one example, the interface indicator portion 146 includes an interface structure 206, and the contact indicator portion 148 includes one corresponding probe head 208 of the plurality of probes 202. Since the probe head 208 is configured to engage with the interface structure 206, the contact indicator portion 148 contacts the interface indicator portion 146.

[0201] Referring to Figures 1 and 21-23, in one example, the manufacturing system 168 includes a vehicle 160. The vehicle 160 supports a fixture 102 and is configured to move the fixture 102 relative to a work cell 106.

[0202] Referring to Figures 1 and 21, in one example the manufacturing system 168 also includes a track 166. The track 166 runs through the work cell 106. In this example the vehicle 160 includes or takes the form of a cart 164 configured to move along the track 166.

[0203] Referring to Figure 28, in one example, the manufacturing system 168 includes a second work cell 172 and a second automated machine 174. The second automated machine 174 is located in work cell 106 and is configured to perform at least one manufacturing process.

[0204] The manufacturing system 168 also includes a second set of probes 212. The second set of probes 212 is movable relative to the second work cell 172 and the fixture 102. The second set of probes 212 is configured to engage with a mapping mechanism 104. A controller 110 communicates with the second set 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 set of probe positions 214 of the second set of probes 212 engaged with the mapping mechanism 104. The controller 110 is further configured to map the second automated machine 174 to a second fixture position 180 of the fixture 102. Once mapped, the second automated machine 174 performs at least one manufacturing step on the workpiece 170.

[0205] Referring to Figures 10, 20, and 28, in the example of manufacturing system 168, track 166 extends from work cell 106 to a second work cell 172 and passes through the second work cell 172. In other words, track 166 connects work cell 106 to the second work cell 172. As shown in Figures 10, 20, and 28, in one example, work cell 106 and the second work cell 172 are arranged in a continuously connected column. In these examples, manufacturing system 168 is a continuous flow manufacturing system in which at least a portion of one or more manufacturing processes are performed within each work cell. Although only two work cells (e.g., work cell 106 and two work cells 172) are shown as examples in Figures 10, 20, and 28, in other examples, manufacturing system 168 can include any number of work cells.

[0206] In the examples shown in Figures 10, 20, and 28, the entire fixture 102 and the entire workpiece 170 are located in corresponding work cells 106 and 172 as the fixture 102 and workpiece 170 move continuously along the manufacturing system 168. However, in another example, the fixture 102 and workpiece 170 extend between multiple 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 located in work cell 106, while a second portion (or second section) of the fixture 102 and a second portion (or second section) of the workpiece 170 are located in 172. In this example of the manufacturing system 168, the work cell 106 and the second work cell 172 are dependent on each other such that the manufacturing processes performed in the second work cell 172 are based on or add to the processes performed in work cell 106. This configuration is particularly advantageous in examples where the fixture 102 and the workpiece 170 are large, elongated structures. For example, the workpiece 170 may be a spar, airfoil, or fuselage section of an aircraft, and the fixture 102 is a fastener configured to support and securely hold the large workpiece 170.

[0207] In other examples of the manufacturing system 168 (not shown), the work cell 106 and the second work cell 172 are located separately and are independent of each other. In this example, a vehicle 160 (e.g., an automated guided vehicle 162) is configured to move along a predetermined travel path to move the fixture 102 and the workpiece 170 between different work cells.

[0208] In the example shown here, the mounting fixture 102 is a rigid body, and the matching mechanism 104 is connected to the mounting fixture 102. However, in other examples, the mounting fixture 10 and the vehicle 160 form a rigid body. For example, the mounting fixture 102 and the vehicle 160 may be integrated into a single component. In such examples, the position of the matching mechanism 104 is also fixed relative to the vehicle 160. For example, the matching mechanism 104 may be connected to, positioned on, or associated with the vehicle 160 rather than the mounting fixture 102.

[0209] As described herein, the positioning and mapping process advantageously allows the fixture 102 and workpiece 170 to be moved to approximate positions within the work cell 106 relative to the automated machine 128. For example, the nearest position of the fixture 102 (e.g., fixture position 118), as determined by the gripper 108, sensor 184, or probe 202 described above, becomes the work position 258, and the automated machine 128 maps itself from the fixture position 118. This process improves the cycle time of the manufacturing process by eliminating the need for incremental mapping of the automated machine 128 to the workpiece 170 and the need to set up the workpiece 170 in a specific predetermined position using non-movable fixtures.

[0210] As described herein, the positioning and alignment process also advantageously allows subsequent fixtures 102 and workpieces 170 to be positioned at moderately different working positions within the work cell 106 and relative to the automated machine 128. In other words, the working position 258 of the fixtures 102 and workpieces 170 in which the manufacturing process is carried out does not need to be the same, fixed, and repeatable position for subsequent workpieces 170.

[0211] Although not explicitly shown, in one or more examples of the mapping device 100 and / or the manufacturing system 168, the interface device 220 includes a combination of (e.g., two or more) of the gripper 108, sensor 184, and / or probe 202. The combination of the gripper 108, sensor 184, and / or probe 202 interfaces with the corresponding mapping mechanism 104 and is used to position and map the fixture 102 based on the position of the mapping mechanism 104.

[0212] Figure 29 is a flowchart of an example of manufacturing method 1000. Referring broadly to Figures 1-10 and especially Figure 29, manufacturing method 1000 includes a step (block 1002) of fixing the workpiece 170 to the fixture 102. With the workpiece 170 fixed to the fixture 102, the position of the workpiece 170 (workpiece position 262) is fixed and known in relation to the fixture 102. In addition, the geometry of the workpiece 170 (workpiece geometry 268) is known. Positioning the fixture 102 relative to the work cell 106 (for example, relative to the reference frame 216) according to method 1000 is consequently equivalent to positioning the workpiece 170 relative to the work cell 106 (for example, relative to the reference frame 216).

[0213] Method 1000 includes the step (block 1004) of moving the fixture 102 relative to the work cell 106. Method 1000 also includes the step (block 1006) of engaging the mapping mechanism 104 with the gripper 108. The position of the mapping mechanism 104 (mapping mechanism position 116) is fixed and known relative to the fixture 102. In one example, the mapping mechanism 104 is connected to the fixture 102. With the gripper 108 engaged with the mapping mechanism 104, Method 1000 further includes the step (block 1010) of positioning the fixture 102 relative to the work cell 106 from the position of the gripper 108 (gripper position 114).

[0214] Method 1000 includes the step (block 1016) of associating the automatic machine 128 with the position of the fixture 102 (fixture position 118). According to Method 1000, associating the automatic machine 128 with the position of the fixture 102 (fixture position 118) is indirectly associating the automatic machine 128 with the position of the workpiece 170 (workpiece position 262). Method 1000 further includes the step (block 1018) of using the automatic machine 128 to perform at least one manufacturing process on the workpiece 170. With the automatic machine 128 associated with the position of the fixture 102 (fixture position 118), the geometry of the workpiece 170 (workpiece geometry 268) and the position of the workpiece 170 relative to the fixture 102 (workpiece position 262) are incorporated into and described by the programmed toolpath of the automatic machine 128 during the execution of the manufacturing process.

[0215] In one example, Method 1000 includes the step (block 1008) of determining the position (gripper position 114) of the gripper 108 relative to the work cell 106, for example, the reference frame 216, in at least one dimension of the fixed coordinate system 112. Method 1000 also includes the step (block 1012) of determining the position (mapping mechanism position 116) of the mapping mechanism 104 relative to the work cell 106, for example, the reference frame 216, in at least one dimension of the fixed coordinate system 112, from the position (gripper position 114) of the gripper 108. Method 1000 further includes the step (block 1014) of the mounting fixture 102 relative to the work cell 106, for example, the reference frame 216, in at least one dimension of the fixed coordinate system 112, from the position (mapping mechanism position 116) of the mapping mechanism 104.

[0216] In one example, Method 1000 includes the step of registering a digital model 120 representing the mounting fixture 102 and the mapping mechanism 104 at the location of the mapping mechanism 104 (mapping mechanism location 116). Method 1000 also includes the step of converting the location of the digital model 120 (model location 126) registered at the location of the mapping mechanism 104 (mapping mechanism location 116) to the location of the mounting fixture 102 (mounting fixture location 118). In other words, when the digital model 120 is registered at the location of the mapping mechanism 104 (mapping mechanism location 116), it is assumed that the location of the mounting fixture 102 (mounting fixture location 118) is the same as the location of the digital model 120 (model location 126) (within tolerance).

[0217] In one example, method 1000 includes the step of moving the fixture 102 to a working position 258 (for example, within the working envelope 140 of the working cell 106) using the gripper 108 while performing (for example, almost simultaneously) the steps of determining the position of the gripper 108 (gripper position 114) and determining the position of the matching mechanism 104 (matching mechanism position 116) (block 1008).

[0218] In one example, Method 1000 includes, for example, the step of engaging the interface indicator portion 146 of the mapping mechanism 104 with the contact indicator portion 148 of the gripper 108 when performing the step of engaging the mapping mechanism 104 with the gripper 108 (block 1004). Method 1000 also includes the step of generating gripper position data 238 representing the XYZ coordinates of the contact point between the contact indicator portion 148 and the interface indicator portion 146.

[0219] In one example, Method 1000 includes the step of gripping the plate 150 of the matching mechanism 104 with the jaw assembly 144 of the gripper 108. Method 1000 also includes the step of engaging the interface index portion 146 connected to the plate 150 with the contact index portion connected to the jaw assembly 144.

[0220] Figure 30 is a flowchart of an example of manufacturing method 2000. Referring broadly to Figures 1 and 11-20, and especially to Figure 30, in one example method 3000 includes a step (block 2002) of fixing the workpiece 170 to the fixture 102. With the workpiece 170 fixed to the fixture 102, the position of the workpiece 170 (workpiece position 262) is fixed and known relative to the fixture 102. In addition, the geometry of the workpiece 170 (workpiece geometry 268) is known. Positioning the fixture 102 relative to the work cell 106 (for example, relative to the reference frame 216) according to method 1000 is consequently equivalent to positioning the workpiece 170 relative to the work cell 106 (for example, relative to the reference frame 216).

[0221] Method 2000 includes the step (block 2004) of moving the fixture 102 relative to the work cell 106. Method 2000 also includes the step (block 2006) of detecting the mapping mechanism 104 by a sensor 184 (e.g., visually identifying it). The position of the mapping mechanism 104 (mapping mechanism position 116) is fixed and known relative to the fixture 102. In one example, the mapping mechanism 104 is located on the fixture 102. Method 2000 further includes the step (block 2008) of positioning the fixture 102 relative to the work cell 106 from the position of the mapping mechanism 104 (mapping mechanism position 116) detected by the sensor 184.

[0222] Method 2000 also includes the step (block 2014) of associating the automated machine 128 with the position of the fixture 102 (fixture position 118). According to Method 2000, associating the automated machine 128 with the position of the fixture 102 (fixture position 118) is indirectly associating the automated machine 128 with the position of the workpiece 170 (workpiece position 262). Method 2000 further includes the step (block 2016) of using the automated machine 128 to perform at least one manufacturing process on the workpiece 170. With the automated machine 128 associated with the position of the fixture 102 (fixture position 118), the geometry of the workpiece 170 (workpiece geometry 268) and the position of the workpiece 170 relative to the fixture 102 (workpiece position 262) are incorporated into and described by the programmed toolpath of the automated machine 128 during the execution of the manufacturing process.

[0223] In one example, Method 2000 includes the step (block 2010) of determining the position of the mapping mechanism 104 (mapping mechanism position 116) relative to the working cell 106, for example, the reference frame 216, in at least one dimension of the fixed coordinate system 112, from sensor data 186 generated by the sensor 184. Method 2000 also includes the step (block 2012) of determining the position of the fixture 102 (fixture position 118) relative to the working cell 106, for example, the reference frame 216, in at least one dimension of the fixed coordinate system 112, from the position of the mapping mechanism 104 (mapping mechanism position 116).

[0224] In one example, Method 2000 includes the step of registering a digital model 120 representing the mounting fixture 102 and the mapping mechanism 104 at the location of the mapping mechanism 104 (mapping mechanism location 116). Method 2000 also includes the step of converting the location of the digital model 120 (model location 126) registered at the location of the mapping mechanism 104 (mapping mechanism location 116) to the location of the mounting fixture 102 (mounting fixture location 118). In other words, when the digital model 120 is registered at the location of the mapping mechanism 104 (mapping mechanism location 116), it is assumed that the location of the mounting fixture 102 (mounting fixture location 118) is the same as the location of the digital model 120 (model location 126) (within tolerance).

[0225] In one example, Method 2000 includes the step of using a sensor 184 to detect (e.g., visually identify) at least one interface structure 192 of the mapping mechanism 104 located on the surface 194 of the mounting fixture 102. Method 2000 also includes the step of generating sensor data 186 representing the XYZ coordinates of the interface structure 192.

[0226] Figure 31 is a flowchart of an example of manufacturing method 3000. Referring broadly to Figures 1 and 21-28, and in particular to Figure 30, manufacturing method 3000 includes a step (block 3002) of fixing the workpiece 170 to the fixture 102. With the workpiece 170 fixed to the fixture 102, the position of the workpiece 170 (workpiece position 262) is fixed and known in relation to the fixture 102. In addition, the geometry of the workpiece 170 (workpiece geometry 268) is known. Positioning the fixture 102 relative to the work cell 106 (for example, relative to the reference frame 216) according to method 1000 is consequently equivalent to positioning the workpiece 170 relative to the work cell 106 (for example, relative to the reference frame 216).

[0227] Method 3000 includes the step (block 3004) of moving the fixture 102 relative to the work cell 106. Method 3000 also includes the step (block 3006) of engaging the mapping mechanism 104 with the plurality of probes 202. The position of the mapping mechanism 104 (mapping mechanism position 116) is fixed and known in relation to the fixture 102. In one example, the mapping mechanism 104 is connected to the fixture 102. Method 3000 further includes the step (block 3010) of positioning the fixture 102 relative to the work cell 106 from the position of the plurality of probes 202 (plural probe positions 204) with respect to the work cell 106, with the plurality of probes 202 engaged with the mapping mechanism 104.

[0228] Method 3000 further includes the step (block 3016) of associating the automatic machine 128 with the position of the fixture 102 (fixture position 118). According to Method 3000, associating the automatic machine 128 with the position of the fixture 102 (fixture position 118) is indirectly associating the automatic machine 128 with the position of the workpiece 170 (workpiece position 262). Method 3000 further includes the step (block 3018) of using the automatic machine 128 to perform at least one manufacturing process on the workpiece 170. With the automatic machine 128 associated with the position of the fixture 102 (fixture position 118), the geometry of the workpiece 170 (workpiece geometry 268) and the position of the workpiece 170 relative to the fixture 102 (workpiece position 262) are incorporated into and described by the programmed toolpath of the automatic machine 128 during the execution of the manufacturing process.

[0229] In one example, Method 3000 includes the step (block 3008) of determining the positions (multiple probe positions 204) of a plurality of probes 202 relative to a work cell 106, for example, a reference frame 216, in at least one dimension of the fixed coordinate system 112. Method 3000 also includes the step (block 3012) of determining the position (mapping mechanism position 116) of a mapping mechanism 104 relative to a work cell 106, for example, a reference frame 216, in at least one dimension of the fixed coordinate system 112, from the positions (multiple probe positions 204) of the plurality of probes 202. Method 3000 further includes the step (block 3014) of a mounting fixture 102 relative to a work cell 106, for example, a reference frame 216, from the position (mapping mechanism position 116) of the mapping mechanism 104.

[0230] In one example, Method 3000 includes the step of registering a digital model 120 representing the mounting fixture 102 and the mapping mechanism 104 at the location of the mapping mechanism 104 (mapping mechanism location 116). Method 3000 also includes the step of converting the location of the digital model 120 (model location 126) registered at the location of the mapping mechanism 104 (mapping mechanism location 116) to the location of the mounting fixture 102 (mounting fixture location 118). In other words, when the digital model 120 is registered at the location of the mapping mechanism 104 (mapping mechanism location 116), it is assumed that the location of the mounting fixture 102 (mounting fixture location 118) is the same as the location of the digital model 120 (model location 126) (within tolerance).

[0231] In one example, Method 3000 includes the step of moving the fixture 102 to a working position 258 (e.g., within the working envelope 140 of the working cell 106). Method 3000 also includes the step of moving a plurality of probes 202 along at least one dimension of the fixed coordinate system 112 to make contact with the mapping mechanism 104.

[0232] In one example, Method 3000 includes, for example, the step of engaging the interface indicator portion 146 of the mapping mechanism 104 with the contact indicator portion 148 of each probe 202 when performing the step of engaging the mapping mechanism 104 with a plurality of probes 202 (block 3006). Method 3000 also includes the step of generating probe position data 254 representing the XYZ coordinates of the contact point between the contact indicator portion 148 and the interface indicator portion 146.

[0233] In one example, method 3000 includes the step of engaging the interface structure 206 of the mapping mechanism 104 with the probe head 208 of the probe 202. Method 1000 also includes the step of engaging the interface indicator portion 146 formed by the interface structure 206 with the contact indicator portion 148 formed by the probe head 208.

[0234] Figure 32 schematically illustrates an example of the controller 110, more specifically, a computing device 224 of the controller 110. The controller 110 includes any suitable programmable controller configured to control one or more manufacturing processes and to perform one or more computing or data processing operations. The processes performed by various examples of the mapping apparatus 100, manufacturing system 168 and methods 1000, 2000, 3000 and / or parts thereof are carried out under computer control provided by the controller 110. The controller 110 may be any number of programmable controllers and / or may include any number of computing devices 224.

[0235] Computing device 224 is an example of a data processing system used to perform one or more of the functions provided by the mapping device 100 and manufacturing system 168 of the disclosure, or to perform one or more of the operational steps of the methods 1000, 2000, and 3000 of the disclosure. Computing device 224 includes a processor unit 604, memory 606, fixed storage device 608, communication unit 610, input / output ("I / O") unit 612, and a communication bus 602 that provides communication between the display 614.

[0236] The communication bus 602 includes one or more buses, such as a system bus or an input / output bus. The communication bus 602 is implemented using any suitable type of architecture that provides data transfer between different components or devices mounted on the bus system.

[0237] The processor unit 604 is any appropriately programmed computer processor configured to execute instructions, such as software instructions, loaded into memory 606. Depending on the implementation of the controller 110, the processor unit 604 may be any number of processors, a multiprocessor core, a microprocessor, or any other type of processor.

[0238] Memory 606 and fixed storage device 608 are examples of storage devices 616. Storage device 616 is any hardware capable of storing information including, but not limited to, temporary and / or persistent data, functional program code, and / or other suitable information. For example, memory 606 may be random-access memory or any other suitable volatile or non-volatile storage device. Memory 606 is also called a non-temporary computer-readable storage medium.

[0239] The fixed storage device 608 can take various forms depending on the implementation. The fixed storage device 608 may include one or more components or devices. For example, the fixed storage device 608 may be a hard drive, flash memory, a rewritable optical disk, a rewritable magnetic tape, or any combination thereof.

[0240] The communication unit 610 provides communication with other data processing systems or devices, such as wired and / or wireless communication links. The communication unit 610 may include one or more devices used to send and receive data, such as a network interface card, modem, or network adapter.

[0241] The input / output unit 612 enables data input and output with other devices connected to the controller 110. For example, the input / output unit 612 can provide a connection for input via a keyboard, mouse, and / or any other suitable input device. Furthermore, the input / output unit 612 can send output to the display 614 for displaying information.

[0242] Instructions for the operating system, applications, and / or programs may be located in a storage device 616 that communicates with the processor unit 604 via a communication bus 602. In one example, the computer implementation instructions are in functional form on a fixed storage device 608. The instructions are loaded into memory 606 for execution by the processor unit 604. One or more of the processes and / or steps described herein are executed by the processor unit 604 using the computer implementation instructions.

[0243] Computer implementation 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 of the processor unit 604. The program code can be implemented on different physical or computer-readable storage media, such as memory 606 or fixed storage device 608.

[0244] In one example, program code 618 is a functional form on a selectively removable computer-readable medium 620 that can be loaded or transferred to a computing device 224 for execution by a processor unit 604. In one example, program code 618 and the computer-readable medium 620 form a computer program product 622. The computer-readable medium 620 may be a computer-readable storage medium 624 or a computer-readable signaling medium 626.

[0245] The computer-readable storage medium 624 may include, but is not limited to, an optical or magnetic disk inserted into or placed in a drive or other device that is part of the fixed storage device 608 for transfer to a storage device such as a hard drive that is part of the fixed storage device 608. The computer-readable storage medium 624 may take the form of a fixed storage device such as a hard drive, thumb drive, network device, cloud, flash memory, optical disk, or magnetic disk. The computer-readable storage medium 624 is connected to or otherwise transferred to the computing device 224.

[0246] In one example, the processes performed by various examples of the mapping device 100 and manufacturing system 168 of the Disclosure, and the operational steps implemented by various examples of the methods 1000, 2000, 3000 and / or parts thereof of the Disclosure, may be implemented as a computer program product comprising a non-temporary computer-readable memory medium and computer control instructions stored in the non-temporary computer-readable memory medium, which are executed by a computer processor, or such computer program product may be utilized.

[0247] Accordingly, various implementations of the apparatus, systems, and methods described herein may be realized in digital electronic circuits, integrated circuits, specially designed ASICs (application-specific integrated circuits), computer hardware, firmware, software, and / or combinations thereof. Various implementation forms may include implementations in one or more computer programs executable and / or interpretable on a programmable system including at least one programmable processor, which may be for special or general purposes, coupled to receive and transmit data and instructions from a storage system, at least one input device, and at least one output device.

[0248] A computer program (also called a program, software, software application, or code) includes 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 disks, optical disks, memory, programmable logic devices (PLDs)) used to provide machine instructions and / or data to a programmable processor, including machine-readable medium that receives machine instructions as machine-readable signals. The term “machine-readable signal” refers to any signal used to provide machine instructions and / or data to a programmable processor.

[0249] One or more of the examples described herein relate to fully automated manufacturing systems and processes, but in one or more other examples, the matching device 100, manufacturing system 168, and methods 1000, 2000, 3000 are used in conjunction with partially automated or manual manufacturing systems and processes, where the fixture 102 is positioned relative to a work station to perform one or more manufacturing processes on the workpiece 170, and the manufacturing machine is associated with the fixture 102. Such manufacturing processes include subtraction, addition, and assembly processes performed on the workpiece 170. In one example, the manufacturing process is: After curing This is performed on composite materials or other materials. Another example is a manufacturing process such as a composite layup process and a composite lamination process. Before curing This is performed on composite materials.

[0250] Next, referring to Figures 33 and 34, as shown in the flowchart of Figure 33 and the aircraft 1200 schematically shown in Figure 34, examples of the correspondence device 100, the manufacturing system 168, and the methods 1000, 2000, and 3000 can be used in connection with the aircraft manufacturing and operation methods 1100.

[0251] Figure 34 shows an example of aircraft 1200. Aircraft 1200 includes a fuselage 1202 and several high-level systems 1204. Examples of high-level systems 1204 include one or more of the propulsion system 1208, electrical system 1210, hydraulic system 1212, and environmental system 1214. In another example, aircraft 1200 may include any number of other types of systems, such as a communication system and a guidance system. The workpiece 170 may be any one of the following: a structure, assembly, subassembly, component, and part of the fuselage 1202 or interior 1206. For example, the workpiece 170 may be any one of the following: a spar of an aircraft, an airfoil, a fuselage section, an interior panel, an exterior skin panel, etc.

[0252] As shown in Figure 33, prior to the start of production, the aircraft manufacturing and operation method 1100 may include the specification and design of the aircraft 1200 (block 1102) and the procurement of materials (block 1104). During the manufacture of the aircraft 1200, component and subassembly manufacturing (block 1106) and system integration (block 1108) may be carried out. Subsequently, the aircraft 1200 is licensed and delivered (block 1110) and put into operation (block 1112). Routine maintenance and upkeep (block 1114) may include the modification, reconfiguration, and refurbishment of one or more systems of the aircraft 1200.

[0253] Each of the processes of the aircraft manufacturing and operation method 1100 shown in Figure 33 may be carried out or performed by a system integrator, a third party, and / or an operator (e.g., a customer). In this specification, 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, leasing company, military organization, service organization, etc.

[0254] Examples of the mapping 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 operation method 1100 shown in the flowchart of Figure 33. In one example, the implementation of the mapping apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 disclosed may form part of the manufacturing of components and subassemblies (block 1106) and / or system integration (block 1108). For example, an aircraft 1200, airframe 1202 and / or assemblies of their components using an implementation of the mapping apparatus 100, manufacturing system 168, and methods 1000, 2000, 3000 disclosed may correspond to the manufacturing of components and subassemblies (block 1106) and may be prepared in a similar manner to components or subassemblies prepared while the aircraft 1200 is in operation (block 1112). Furthermore, the implementations of the disclosure mapping device 100, the manufacturing system 168, and the methods 1000, 2000, and 3000 may be used during system integration (block 1108) and authorization and delivery (block 1110). Similarly, the implementations of the disclosure mapping device 100, the manufacturing system 168, and the methods 1000, 2000, and 3000 may be used, for example, during the operation (block 1112) and maintenance and servicing (block 1114) of the aircraft 1200.

[0255] Referring to Figures 1 and 34, the disclosure includes a method for producing a portion of aircraft 1200 (Figure 34) using a matching device 100 (Figure 1) and a method for producing a portion of aircraft 1200 using a manufacturing system 168 (Figure 1). Referring to Figures 29 and 34, the disclosure includes a portion of aircraft 1200 assembled according to method 1000 (Figure 29). Referring to Figures 30 and 34, the disclosure includes a portion of aircraft 1200 assembled according to method 2000 (Figure 30). Referring to Figures 31 and 34, the disclosure includes a portion of aircraft 1200 assembled according to method 3000 (Figure 31). A portion of aircraft 1200 includes one or more structures, components, parts, assemblies, and subassemblies from among the airframe 1202, interior 1206, and high-level systems 1204.

[0256] As used herein, a system, apparatus, device, structure, article, element, component, or hardware “configured” to perform a particular function is capable of performing that function without any modification, rather than merely having the potential to perform that function after further modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware “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 ~” means an existing characteristic of the 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. In this disclosure, a system, apparatus, device, structure, article, element, component, or hardware described as “configured” to perform a particular function may additionally or alternatively be described as “adapted” and / or “operating” to perform that function.

[0257] In this disclosure, the terms “coupled,” “coupling,” and similar terms refer to two or more elements that are joined, connected, fastened, fitted, connected, communicated with, or otherwise related (e.g., mechanically, electrically, fluidly, optically, or electromagnetically) to one another. In various examples, these elements may be directly related or indirectly related. For example, element A may be directly related to element B. In another example, element A may be indirectly related to element B, for example, through another element C. Not all relationships between the various elements disclosed are necessarily represented. Therefore, connections other than those shown in the figures may exist.

[0258] As used herein, the terms “about” and “near” refer to or represent a state that is close to the described state but not exactly, yet still performs the desired function or produces the desired result. For example, the terms “about” and “near” refer to a state that is within a given acceptable tolerance or precision. For example, the terms “about” and “near” refer to a state that is within 10% of the described state. However, the terms “about” and “near” do not exclude a state that is exactly as described.

[0259] In the above-referenced Figures 1, 7, 16, 25, 32, and 34, blocks represent functional elements, features, or components thereof, and the lines connecting the various blocks do not necessarily implicitly signify a specific configuration. Therefore, the illustrated configurations may be modified, added to, and / or omitted. Furthermore, those skilled in the art will understand that not all elements shown and illustrated in the above-referenced Figures 1-29, 32, and 34 are necessarily included in all examples, and not all elements described herein are necessarily depicted in every example. Unless otherwise specified, the schematic diagrams of the examples depicted in the above-referenced Figures 1-29, 32, and 34 do not implicitly imply any structural limitations with respect to the examples. Rather, it should be understood that even if one exemplary configuration is shown, it may be modified as appropriate.

[0260] In Figures 29-31 and 33 referenced above, blocks represent processes, steps, and / or parts thereof, and the lines connecting the various blocks do not implicitly signify a specific order or dependency of the processes or parts thereof. It should be understood that not all dependencies between the various processes disclosed are necessarily represented. Figures 29-31 and 33 and any accompanying disclosures describing the processes of the methods disclosed herein should not be interpreted as necessarily determining the order in which the processes should be performed. Rather, it should be understood that even if one exemplary order is shown, the order of those processes may be modified as appropriate. Therefore, modifications, additions, and / or omissions may be made to the exemplary processes, and certain processes may be performed in different orders or simultaneously. Furthermore, those skilled in the art will understand that it is not necessary to perform all the processes described.

[0261] Furthermore, throughout this Specification, references to features, advantages, or similar expressions used herein do not implicitly mean that all features and advantages that may be realized in the examples disclosed herein should be or are any single example. Rather, expressions referring to features and advantages are understood to mean that a particular feature, advantage, or characteristic described in relation to an example is included in at least one example. Accordingly, discussions of features, advantages, and similar expressions used throughout this Disclosure may, but not necessarily, refer to the same example.

[0262] The described features, advantages, and characteristics of one example can be combined in any suitable way in one or more other examples. Those skilled in the art will recognize that the examples described herein can be implemented without one or more of the specific features or advantages of a particular example. In other examples, additional features and advantages that may not be present in all examples may be recognized in a particular example. Further, although various examples of the associating device 100, the manufacturing system 168, and the methods 1000, 2000, 3000 have been shown and described, modifications will occur to those skilled in the art upon reading this specification. This application includes such modifications and is limited only by the claims.

[0263] The following examples are also provided herein, but these should not be confused with the appended claims and are related to the following.

[0264] 1. An associating device, comprising: - a fixture movable with respect to a work cell; - an associating mechanism fixed to the fixture; - a sensor configured to detect the associating mechanism; and - a controller in communication with the sensor; the controller is configured to position the fixture with respect to the work cell from an associating mechanism position of the associating mechanism identified by the sensor. The associating device.

[0265] 2. The device according to Example 1, wherein the controller is further configured to determine an associating mechanism position of the associating mechanism in at least one dimension of a fixed coordinate system from sensor data generated by the sensor; and to determine a fixture position of the fixture in at least one dimension of the fixed coordinate system from the associating mechanism position of the associating mechanism.

[0266] 3. The apparatus described in Example 2, wherein the controller is further configured to register digital models representing the mounting fixture and the mapping mechanism at the mapping mechanism position of the mapping mechanism; and to convert the model position of the digital model registered at the mapping mechanism position to the mounting fixture position of the mounting fixture.

[0267] 4. The apparatus according to Embodiment 2 or 3, wherein the controller is further configured to associate the automatic machine with the mounting position of the mounting fixture.

[0268] 5. The apparatus described in Example 4, wherein the mounting fixture is Before curing Includes a mandrel configured to support a composite laminate; and the automatic machine Before curing For composite laminated materials Before curing A device configured to carry out a manufacturing process.

[0269] 6. The apparatus described in Example 4 or 5, wherein the mounting fixture is After curing A retaining mechanism configured to fix a composite material structure; and an automatic machine, After curing For composite material structures After curing A device configured to carry out a manufacturing process.

[0270] 7. The apparatus according to any one of Embodiments 4 to 6, wherein the sensor is connected to an automated machine, and the automated machine is configured to move the sensor relative to a mounting fixture.

[0271] 8. The apparatus according to any one of Examples 1 to 7, wherein the sensor comprises at least one of a camera and a laser scanner.

[0272] 9. The apparatus according to any one of Examples 1 to 8, wherein the mounting mechanism includes an interface structure located on the surface of the mounting fixture.

[0273] 10. The apparatus according to Example 9, wherein the interface structure is visually perceptible by a sensor.

[0274] 11. A method for manufacturing a part of an aircraft using the apparatus according to any one of Examples 1 to 10.

[0275] 12. A manufacturing system comprising: - a machine located within a work cell and configured to perform at least one manufacturing process; - a fixture configured to support a workpiece and movable with respect to the work cell; - an association mechanism fixed to the fixture; - a sensor configured to detect the association mechanism; - a controller in communication with the sensor and the machine wherein: - the controller is configured to position the fixture with respect to the work cell from the association mechanism position of the association mechanism identified by the sensor, and - the controller is further configured to associate the machine with the fixture position of the fixture. A manufacturing system.

[0276] 13. The system according to Example 12, wherein the controller is further configured to: - determine the association mechanism position of the association mechanism in at least one dimension of a fixed coordinate system from sensor data generated by the sensor; and - determine the fixture position of the fixture in at least one dimension of the fixed coordinate system from the association mechanism position of the association mechanism. A system.

[0277] 14. The system according to Example 12 or 13, wherein the controller is further configured to register a digital model representing the fixture and the association mechanism at the association mechanism position of the association mechanism; and to convert the model position of the digital model registered at the association mechanism position to the fixture position of the fixture.

[0278] 15. A system according to any one of Examples 12 to 14, wherein the fixture includes a mandrel configured to support a composite laminate; and the automated machine includes an automated fiber placement machine.

[0279] 16. A system according to any one of Examples 12 to 15, — The sensor is connected to the automated machine, — The automated machine is configured to move the sensor relative to the mounting fixture. system.

[0280] 17. The system according to any one of Examples 12 to 16, wherein the matching mechanism includes an interface structure located on the surface of the mounting fixture and visually perceptible by a sensor.

[0281] 18. A system according to any one of Examples 12 to 17, further comprising a vehicle configured to support a fixture and move the fixture relative to a work cell, wherein the vehicle comprises either an automated guided vehicle or a cart configured to move along a track (166) through the work cell.

[0282] 19. A system according to any one of Examples 12 to 18, — The second working cell, — A second automated machine located within the second work cell and configured to perform at least one manufacturing process, — Further including a second sensor configured to detect a matching mechanism, here — The controller communicates with the second sensor and the second automatic machine; The controller is configured to position the fixture relative to the second work cell from the second matching mechanism position of the matching mechanism, which is identified by the second sensor; and, — The controller is further configured to associate the second automatic machine with the second mounting position of the mounting fixture. system.

[0283] 20. A method for manufacturing a part of an aircraft using the system described in any one of Examples 12 to 19.

[0284] 21. A manufacturing method, — Moving the mounting fixture relative to the work cell, — Detecting the matching mechanism with a sensor, — Positioning the mounting fixture relative to the work cell based on the position of the matching mechanism detected by the sensor, — Matching the mounting position of the mounting fixture with the automated machine. A manufacturing method that includes this.

[0285] 22. The method described in Example 21, — Determining the position of the mapping mechanism in at least one dimension of a fixed coordinate system from sensor data generated by the sensor; and — Determining the position of a mounting fixture in at least one dimension of a fixed coordinate system from the position of the matching mechanism. Methods that further include the above.

[0286] 23. The method according to Example 21 or 22, further comprising using a sensor to visually detect at least one interface structure of a mounting mechanism located on the surface of the mounting fixture.

[0287] 24. A portion of an aircraft assembled according to the method described in any one of Examples 21 to 23.

Claims

1. A matching device, A movable fixture (102) relative to the work cell (106), the fixture (102) includes a surface (194) that supports the workpiece (170), A mounting mechanism (104) fixed to the aforementioned mounting fixture (102), A sensor (184) configured to detect the aforementioned matching mechanism (104), The system includes a controller (110) that communicates with the sensor (184), wherein the controller (110) is configured to determine the position of the mounting fixture (102) relative to the reference frame (216) of the work cell (106) from the position of the mapping mechanism (104) relative to the reference frame (216) identified by the sensor (184), The corresponding mechanism (104) includes an interface structure (192) disposed on the surface (194) of the mounting fixture (102), The interface structure (192) is appropriately positioned so as not to be obscured by the workpiece (170), and The interface structure (192) includes a structure that is visually perceptible by the sensor (184) and / or distinguishable by a computer from the surface (194) of the mounting fixture (102). Correspondence device.

2. The controller (110) further, From the sensor data generated by the sensor (184), the position (116) of the correspondence mechanism (104) in at least one dimension (x, y, z) of the fixed coordinate system (112) is determined; and From the corresponding mechanism position (116) of the corresponding mechanism (104), the mounting position (118) of the mounting fixture (102) in at least one dimension (x, y, z) of the fixed coordinate system (112) is determined. The apparatus according to claim 1, configured as described above.

3. The controller (110) further, Register a digital model representing the mounting fixture (102) and the matching mechanism (104) at the matching mechanism position (116) of the matching mechanism (104); and The model position of the digital model registered at the corresponding mechanism position (116) is converted to the mounting fixture position (118) of the mounting fixture (102). It is composed of, And / or the controller (110) is further configured to associate the automatic machine (128) with the mounting position (118) of the mounting fixture (102), The apparatus according to claim 2.

4. The mounting fixture (102) includes a mandrel (130) configured to support the pre-cured composite laminate; the automatic machine (128) is configured to perform a pre-curing manufacturing process on the pre-cured composite laminate; and / or The mounting fixture (102) includes a holding mechanism (260) configured to fix the post-cured composite material structure; the automatic machine (128) is configured to perform a post-cured manufacturing process on the post-cured composite material structure; and / or The sensor (184) is connected to the automatic machine (128); the automatic machine (128) is configured to move the sensor (184) relative to the mounting fixture (102), The apparatus according to claim 3.

5. The apparatus according to any one of claims 1 to 4, wherein the sensor (110) includes at least one of a camera and a laser scanner.

6. The apparatus according to any one of claims 1 to 5, wherein the interface structure (192) is continuous and extends longitudinally along the surface (194) of the mounting fixture (102).

7. The apparatus according to any one of claims 1 to 6, further comprising an interface device (220) configured to interact with the mapping mechanism (104) and to identify the position of the mapping mechanism (104) relative to the reference frame (216) within the work cell (106), wherein the interface device (220) is configured to generate interface data (222) representing the position of the mapping mechanism (104) relative to the reference frame (216) or the position of the mapping mechanism (116).

8. A manufacturing system (168), An automated machine (128) located within a work cell (106) and configured to perform at least one manufacturing process, A mounting fixture (102) having a surface (194) configured to support a workpiece (170), wherein the mounting fixture (102) is movable relative to the work cell (106), A mounting mechanism (104) fixed to the aforementioned mounting fixture (102), A sensor (184) configured to detect the aforementioned matching mechanism (104), The sensor (184) and the controller (110) that communicates with the automatic machine Includes, The matching mechanism (104) includes an interface structure (192) disposed on the surface (194) of the mounting fixture (102), wherein the interface structure (192) is appropriately positioned so as not to be obscured by the workpiece (170), and the interface structure (192) includes a structure that is visually perceptible by the sensor (184) and / or distinguishable by a computer from the surface (194) of the mounting fixture (102), The controller is configured to determine the position of the mounting fixture relative to the reference frame (216) of the work cell (106) from the position of the mapping mechanism (116) of the mapping mechanism (104) relative to the reference frame (216) of the work cell (106), which is identified by the sensor (184), and the controller is further configured to associate the automatic machine with the mounting fixture position (118) of the mounting fixture (102). Manufacturing system (168).

9. The controller (110) further, From the sensor data generated by the sensor (184), the position (116) of the correspondence mechanism (104) in at least one dimension of the fixed coordinate system (112) is determined; and From the corresponding mechanism position (116) of the corresponding mechanism (104), the mounting position (118) of the mounting fixture (102) in at least one dimension of the fixed coordinate system (112) is determined. It is composed of, And / or the controller (110) further, A digital model representing the mounting fixture and the corresponding mechanism is registered at the corresponding mechanism position of the corresponding mechanism; and The system according to claim 8, configured to convert the model position of the digital model registered at the corresponding position of the mounting mechanism to the mounting position of the mounting fixture.

10. The mounting fixture (102) comprises a mandrel (130) configured to support a composite laminate, and the automatic machine (128) comprises an automatic fiber placement machine; and / or The sensor (184) is connected to the automatic machine (128), and the automatic machine (128) is configured to move the sensor relative to the mounting fixture; and / or The system further includes a vehicle configured to support the mounting fixture and to move the mounting fixture relative to the work cell, wherein the vehicle is configured to move along a track (166) through the work cell, and includes either an automated guided vehicle or a cart. The system according to claim 8 or 9.

11. A second working cell (172), A second automated machine (174) located within the second work cell (172) and configured to perform at least one manufacturing process, A second sensor (198) configured to detect the correspondence mechanism (104) and It further includes, The controller communicates with the second sensor and the second automatic machine; The controller is configured to determine the position of the mounting fixture relative to the second work cell from the position of the second mapping mechanism of the mapping mechanism, which is identified by the second sensor; and, The controller is further configured to associate the second automatic machine with the second mounting position of the mounting fixture. The system according to any one of claims 8 to 10.

12. The system according to any one of claims 8 to 11, wherein the interface structure (192) is continuous and extends longitudinally along the surface (194) of the mounting fixture (102).

13. A manufacturing method, Moving the mounting fixture (102) having a surface (194) relative to the work cell, The matching mechanism (104) is detected by the sensor (184), The position of the mounting fixture (102) relative to the reference frame of the work cell is determined from the position of the matching mechanism detected by the sensor (184), The automatic machine is associated with the mounting position of the aforementioned mounting fixture (102) and Includes, A manufacturing method wherein the matching mechanism (104) includes an interface structure (192) disposed on the surface (194) of the mounting fixture (102), the interface structure (192) is appropriately positioned so as not to be obscured by the workpiece (170), and the interface structure (192) is visually perceptible by the sensor (184) and / or distinguishable by a computer from the surface (194) of the mounting fixture (102), and the interface structure (192) is visually detected using the sensor (184).

14. Determining the position (116) of the correspondence mechanism (104) in at least one dimension of a fixed coordinate system (112) from sensor data generated by the sensor; The mounting position (118) of the mounting fixture (102) in at least one dimension of the fixed coordinate system (112) is determined from the position (116) of the corresponding mechanism (104). The method according to claim 13, further comprising:

15. The interface device (220) is made to interact with the matching mechanism (104); To determine the position of the correspondence mechanism (104) with respect to the reference frame (216) within the work cell (106) and The method according to claim 13 or 14, further comprising:

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