Reconfigurable workshop

Abstract

A system (1) for processing or manufacturing a workpiece (7), the system (1) comprising a plurality of moveable modules (3,77) having: anchor points (9) for locating the plurality of moveable modules (3,77) to each other and / or a support surface (5); module connectors (45) arranged to convey media and / or power between adjacent modules (3,77) and / or the support surface (5); and at least some of the plurality of modules (3,77) having tools for interacting with the workpiece (7), wherein the modules (3,77) are moveable and interchangeable to vary processing and manufacturing steps performed on a workpiece (7).

Description

[0001] RECONFIGURABLE WORKSHOP

[0002] The present disclosure relates to a system for processing or manufacturing a workpiece, the system comprising a plurality of moveable modules, and a method of manufacturing or processing one or more articles simultaneously using the system.

[0003] In any field, individual articles are rarely made via a single manufacturing operation or by a single manufacturing process type. As such, individual manufacturing operations and the routing of parts between different manufacturing operations have been a key area for development.

[0004] Over the last century, manufacturing machines have been augmented with more and more automation to require less and less input from a human operator to operate each machine. Most manufacturing machines are optimized for a single type of manufacturing operation such as mechanical milling, turning using a lathe, laser cutting, or additive manufacturing. Much has been done in the area of milling and turning to create “multi-tasking” machines that maximize the flexibility of machines by making them capable of multiple operations. This in turn minimizes the number of setups required within a single machine adding efficiency. A common variant of such a machine is a “mill-turn” multi-tasking machine that combines the functions of milling and turning. Mill-turn machines reduce the number of part movements between different machines.

[0005] For many years, primarily high-volume manufacturing has achieved automated continuous (or semi-continuous) part-flow with the assembly line. While highly automated production lines have high output, they typically have limited flexibility. In contrast, low to medium volume manufacturing still relies heavily on job shops that use batch processing, which preserves flexibility, but normally requires complex routing most often achieved by manually moving parts between machines. Furthermore, there are still difficulties in making very large parts (such as aircraft fuselages, wings, or wind turbines) in which the manufacturing tools must be brought to and moved arranged to reach these large assemblies as the progress.

[0006] Attention is now focused on how to automate the way parts move from one machine to another for workflows that requires multiple processes. A common example of this is to replace human operators with robots who can load and unload parts in a machine and even move them to other machines.

[0007] An alternative approach to moving parts between machines is to use an all-in-one hybrid machine with modular tool heads, where each head is optimized for a different function. WO 2014 / 013247, W02015 / 189600 and WO 2018 / 172774 describe the combining of additive manufacturing techniques with machine tools to facilitate such hybrid manufacturing. These machines allow multiple types of manufacturing steps to be carried out on a part in a single setup (or with reduced set ups). However, the machine tool has legacy elements optimised for manual machine operators that are no longer used. There still also remains a difficulty of processing larger parts with high precision as the difficulty of maintaining precision as the working volume of machine tools (conventional or hybrid) scales up is exponential as reflected by the increased cost, size, and weight.

[0008] The inventors have appreciated that a further approach for increasing the flexibility of a manufacturing environment, and for manufacturing or processing larger parts, is a system in which the machine performing operations on the work piece is reconfigurable by coordinating, combining, temporarily anchoring, and powering multiple automation, environmental, and other units to achieve multi-scale & multi-point processing. This may be referred to as a reconfigurable workshop for “metamorphic manufacturing”.

[0009] It will be appreciated that a reconfigurable workshop may be used to manufacture articles and items and for other processing of such articles and items. In general, in the below, “manufacturing” will be considered to be the making of an article de novo. On the other hand “processing,” will be referred to as any process in which an existing article or item has operations performed on it. This may include, but is not limited to, repair, modification, addition to, removal from, and the like.

[0010] Any article or item being processed will be referred to as a workpiece.

[0011] According to a first aspect of the invention, there is provided a system for processing or manufacturing a workpiece, the system comprising a plurality of moveable modules having: anchor points for locating the plurality of moveable modules to each other and / or a support surface; module connectors arranged to convey media and / or power between adjacent modules and / or the support surface; and at least some of the plurality of modules having tools for interacting with the workpiece, wherein the modules are moveable and interchangeable to vary processing and manufacturing steps performed on a workpiece.

[0012] The system may also include an alignment system configured to determine a relative alignment between the plurality of modules and the workpiece.

[0013] The alignment system may include one or more of: a module shape alignment subsystem configured to determine the deviation of each module from an expected shape and / or the deviation of tool movement in the module from an expected path; a module position alignment sub-system configured to determine a position of each module in a global co-ordinate system; and a workpiece alignment sub-system configured to determine of position of the workpiece in the global co-ordinate system.

[0014] The alignment system may be configured to at least in part control movement of the tools based on the determined relative alignment between the modules and the existing or intended workpiece. The alignment system may control movement of the tools based on an expected alignment determined from an expected and ideal placement of the modules and shape of the modules, and an adjustment to best match from the ideal placement and shape determined by the alignment system.

[0015] The alignment system may be configured to control the tool, at least in part, based on any adjustments determined by analysis of a previous workpiece processed by the system.

[0016] The alignment system may be configured to track the position of the tools relative to the workpiece and modules, during use.

[0017] The plurality of modules may include a set of active modules, the active modules including tools for performing operations on the workpiece.

[0018] The operations may include: adding of material; adding of energy; removal of material; removal of energy; modifying an existing material; inspection of the workpiece; and drilling and / or tapping. At least some of the active modules may comprise processing modules. In the processing modules, the tool may comprise at least one processing or machining head arranged to add, modify or remove material from the workpiece.

[0019] At least some of the active modules may comprise robot modules comprising tools held and moved by a robot arm.

[0020] The tool may be interchangeable.

[0021] The tool may be moveable in one, two, or three, or more axes, relative to the workpiece.

[0022] The system may be arranged to position at least two active modules at opposing positions around the workpiece, such that when the active modules perform operations on the workpiece, the actions from different modules on the workpiece at least part counteract each other

[0023] The actions that at least in part counteract each other may comprise one or more of: applying mechanical forces to oppose mechanical forces applied by the first active module; applying heat to oppose heat or cooling applied by the first active module; applying cooling to oppose heat or cooling applied by the first active module; and invoking environmental conditions to counteract the influence of the first active module; and causing chemical reactions to counteract any influence by the first active /

[0024] The plurality of modules may comprise a set of environmental modules. The environmental modules may be arranged to perform one or more of the following: support further modules of the plurality of modules; provide power and / or media to further modules of the plurality of modules; hold or support the workpiece; move the workpiece in one or more axes; cool the workpiece and / or the environment around the workpiece; heat the workpiece and / or the environment around the workpiece; provide an inert or reactive environment around the workpiece; and extract or remove waste material, media or conditions generated in processing the workpiece. The environmental modules may be arranged to move the workpiece in one or more axes, the axes the environmental module moves the workpiece in being different to the axes the tool is moveable in.

[0025] The environmental modules may be arranged to at least in part counteract the actions of the active modules without performing an operation on the workpiece.

[0026] The plurality of modules may be arranged to process multiple points of the workpiece simultaneously.

[0027] The plurality of modules may be moveable by one or more of: an overhead gantry system; automatically guided vehicles, AGVs; forklift; automated robots; drones; movement systems formed in the modules; and manually by operators.

[0028] The plurality of modules may be moveable around a workpiece, to perform one or more different functions on different portions on the workpiece.

[0029] The workpiece may be moved between different modules, to perform a variety of functions on the workpiece.

[0030] The modules may be arranged with a unit size. The modules may be arranged to be assembled in a three-dimensional grid having periodicity corresponding to a fraction of the unit size to allow an offset of the unit size between modules.

[0031] The grid may comprise a periodicity of half the unit size.

[0032] The plurality of modules may comprise a plurality of spacer modules. The plurality of spacer modules may be arranged to provide a shift of a multiple of one or more of the unit size between modules, a fraction of the unit size between modules, or a change of orientation of modules.

[0033] At least some of the plurality of modules include a fixing system to secure the module to the workpiece. The fixing system may use one or more of: magnetic forces; suction; and mechanical clamping.

[0034] The system may include a base surface. The base surface may have a plurality of base anchor points and / or a plurality of base connectors through which media and / or power are conveyed.

[0035] The base surface may be fixed in the global co-ordinate system.

[0036] A first set of base anchors may include some or all of the base anchor points and may be arranged on a two-dimensional grid comprising a planar lattice with periodicity corresponding to a fraction of the unit size.

[0037] The two-dimensional grid may comprise a planar lattice with periodicity corresponding to a half of the unit size.

[0038] Each anchor point may be arranged at a node of the two-dimensional grid. Each anchor point may comprise a plurality of locator points. Each locator point may be arranged to locate a module in a different position and orientation in the two-dimensional grid.

[0039] The locator points may be arranged in a pattern that mirrors a cell of the grid.

[0040] The system may include a second set of base anchors. The second set of base anchors may be configured to provide a polar arrangement of the plurality of modules. Each base anchor in the second set may include one or more locator point.

[0041] Each locator point may include: a positioning formation in the base surface, arranged to engage a corresponding formation in the module.

[0042] Each locator point may be arranged to provide mechanical alignment of the modules.

[0043] The connectors may be formed in or adjacent to the positioning formations of the locator points.

[0044] The system may comprise separate connector associated with each locator point. Each base anchor may include an alignment point to determine the position of the base anchor in the global co-ordinate system.

[0045] The base surface may include embedded conduits for conveying power and / or media to or from the base connectors.

[0046] In a connection between two connectors, one or both connectors may include a cover arranged to prevent contamination of the connectors.

[0047] The covers may be opened by the process of engaging the connectors.

[0048] The connectors may form at least part of the anchor points.

[0049] The system may comprise a connector device having: a hub located on the base surface; one or more arms extending radially from the hub; and conduits for power or media extending from the base surface, through the hub and the arm, wherein the one or more arms are rotatable and liftable between a first position in which the arms are disengaged with the module and a second position in which the arms engage the module to provide one or more of a connection for power and / or media and / or data and a clamping function.

[0050] At least some of the modules may comprise conduits for conveying power and / or media to the module connectors.

[0051] Control signals may be delivered to the modules and / or tools through the module connectors.

[0052] Each module may have a separate identifier. The control signals for the plurality of modules may be delivered through a common channel. The identifiers may allow each module to be controlled independently.

[0053] The system may comprise a single system controller for operating the plurality of modules and tools. The plurality of modules may be fixed in place by zero-point clamps.

[0054] The media comprises one or more of: processable or feedstock media to be added to or form the workpiece; cooling media; shielding media; heating media; containment media; lubrication media; waste or by-products; and pneumatic or hydraulic media.

[0055] According to a second aspect of the invention, there is provided a method of manufacturing or processing a first article using the system of the first aspect, the method comprising: selecting at least some of the plurality of modules; locating the selected modules on the base surface or on other modules; performing at least part of the manufacturing or processing using the selected modules.

[0056] The manufacturing or processing may comprise a plurality of stages.

[0057] Selecting and locating the modules may comprise selecting and locating single modules or groups of modules, each single module or group of modules corresponding to a different stage. The method may comprise: moving the workpiece between different modules or groups of modules to carry out different stages.

[0058] The method may comprise: locating or positioning modules for later stages after earlier stages are completed.

[0059] The method may comprise: removing or redeploying modules associated with stages that have been completed.

[0060] The method may comprise: whilst a current stage is being carried out, locating and / or redeploying modules removed from earlier stages to carry out later stages.

[0061] For at least two stages, the workpiece may be kept in the same place, and the modules may be moved or rearranged around the workpiece.

[0062] The modules may be moved relative to the workpiece to manufacture or process different portions of the workpiece. The method may comprise: manufacturing or processing a second article, different to the first article. The method may further comprise: rearranging at least some of the plurality of modules to manufacture or process the second article.

[0063] The modules may be rearranged after the first article is complete.

[0064] At least some of the modules may be rearranged whilst the first article is being processed.

[0065] According to a third aspect of the inventions, there is provided a base surface for forming a reconfigurable system for manufacturing or processing a workpiece, the base surface comprising: a plurality of base anchor points for locating a plurality of moveable and interchangeable modules to form the system; a plurality of base connectors arranged to convey media and / or power to and from the modules.

[0066] The base surface may be fixed in a global co-ordinate system defining the reconfigurable system for manufacturing or processing a workpiece.

[0067] A first set of base anchors may include some or all of the base anchor points. The first set of anchors may be arranged on a two-dimensional grid comprising a planar lattice with periodicity corresponding to a fraction of the unit size of the modules. The periodicity may preferably be half of the unit size of the modules.

[0068] Each anchor point may be arranged at a node of the two-dimensional grid. Each anchor point may comprise a plurality of locator points, each locator point arranged to locate a module in a different position and orientation in the two-dimensional grid.

[0069] The locator points may be arranged in a pattern that mirrors a cell of the grid.

[0070] The system may include a second set of base anchors configured to provide a polar arrangement of the modules, each base anchor in the second set including one or more locator point.

[0071] Each locator point may include: a positioning formation in the base surface, arranged to engage a corresponding formation in the module. Each locator point may be arranged to provide mechanical alignment of the modules.

[0072] The connectors may be formed in or adjacent to the positioning formations of the locator points.

[0073] The base surface may comprise a separate connector associated with each locator point.

[0074] Each base anchor may include an alignment point to determine the position of the base anchor in the global co-ordinate system.

[0075] The base surface may include embedded conduits for conveying power and / or media to or from the base connectors.

[0076] According to a fourth aspect of the invention, there is provided a module for forming a reconfigurable system for manufacturing or processing a workpiece, the module comprising: anchor points for locating the module relative to a base surface or other modules; and module connectors arranged to convey media and / or power to and / or from adjacent modules and / or the support surface; wherein the module is arranged to perform one or more functions to process or manufacture the workpiece or to enable manufacturing or processing of the workpiece and wherein the module is moveable and interchangeable to vary the functions performed on a workpiece by placing the module in different locations.

[0077] The module may be an active module including tools for performing operations on the workpiece.

[0078] The operation may be one or more of: adding of material; adding of energy; removal of material; removal of energy; modifying an existing material; inspection of the workpiece; and drilling and / or tapping.

[0079] The module may be a processing module. The tool may comprise at least one processing or machining head arranged to add, modify or remove material from the workpiece.

[0080] The module may be a robot module comprising tools held and moved by a robot arm. The tool may be interchangeable.

[0081] The tool may be moveable in one, two, or three, or more axes, relative to the workpiece.

[0082] The module may be an environmental modules arranged to perform one or more of the following: support further modules of the plurality of modules; and provide power and / or media to further modules of the plurality of modules; hold or support the workpiece; move the workpiece in one or more axes; cool the workpiece and / or the environment around the workpiece; heat the workpiece and / or the environment around the workpiece; provide an inert or reactive environment around the workpiece; and extract or remove waste material, media or conditions generated in processing the workpiece.

[0083] The environment al module may be arranged to move the workpiece in one or more axes.

[0084] The module may be arranged to at least in part counteract the actions of a different active module arranged to perform an operation on the workpiece, the environmental module counteracting the actions of the active module without performing an operation on the workpiece.

[0085] The module may be a spacer module arranged to provide a shift in a plurality of modules arranged on a grid, the shift being a shift of a multiple of one or more of the unit size, a fraction of the unit size, or to provide a change of orientation of modules

[0086] The module may include a fixing system to secure the module to the workpiece.

[0087] The fixing system may use one or more of: magnetic forces suction; and mechanical clamping.

[0088] The first manifold may include a cover arranged to prevent contamination of the connector.

[0089] The cover may be opened by the process of engaging the connectors. The module connector may form at least part of the anchor points.

[0090] The module may comprise conduits for conveying power and / or media to the module connectors.

[0091] Control signals may delivered to the module through the module connectors.

[0092] The module may have an identifier. The control signals for a plurality of modules may be delivered through a common channel, the identifier allowing the module to be controlled independently to the other modules.

[0093] The module may comprise zero-point clamps for securing the modules to a base surface and / or other modules.

[0094] The media may comprise one or more of: processable or feedstock media to be added to or form the workpiece; cooling media; shielding media; heating media; containment media; lubrication media; waste or by-products; and pneumatic or hydraulic media.

[0095] According to a fifth aspect, there is provided a connector device for use with a modular manufacturing system including a plurality of interconnecting modules, the connector device locatable on a base surface and including: a hub locatable on the base surface; one or more arms extending radially from the hub; and conduits for power or media extending from the base surface, through the hub and the arm, wherein the one or more arms are rotatable and liftable between a first position in which the arms are disengaged with the module and a second position in which the arms engage the module to provide one or more of a connection for power and / or media and / or data and a clamping function.

[0096] It will be appreciated that any feature described in relation to a particular aspect may be applied, mutatis mutandis, to any other aspect, unless mutually exclusive.

[0097] Embodiments of the invention will now be described by way of example only, with reference to the following drawings, in which: Figure 1A schematically illustrates a base of a reconfigurable workshop system according to an embodiment of the invention;

[0098] Figure IB schematically illustrates the base with a number of modules in place; Figure 2A illustrates an anchor point from the base of Figure 1 in plan view; Figure 2B schematically illustrates the anchor point of Figure 2A in side view;

[0099] Figure 3 illustrates the general structure of a module of a reconfigurable workshop system according to an embodiment of the invention;

[0100] Figure 4 schematically illustrates a gantry system for moving the modules of Figure 3;

[0101] Figure 5 schematically illustrates an example of a processing module from the reconfigurable workshop system;

[0102] Figure 6 schematically illustrates a first arrangement of modules in the reconfigurable workshop system

[0103] Figure 7 schematically illustrates a second arrangement of modules in the reconfigurable workshop system

[0104] Figure 8 schematically illustrates a third arrangement of modules in the reconfigurable workshop system

[0105] Figure 9 schematically illustrates an example of balanced processing using two robots arms;

[0106] Figure 10 illustrates a method for positioning modules in a reconfigurable workshop system;

[0107] Figure 11 illustrates a first method of operating a reconfigurable workshop to process or manufacture a workpiece;

[0108] Figure 12 illustrates a second method of operating a reconfigurable workshop to process or manufacture a workpiece; and

[0109] Figures 13A and 13B illustrate an alternative arrangement for connecting power and media to a module, and clamping the module in place.

[0110] A first embodiment of a metamorphic manufacturing system 1 will now be described with reference to Figures 1 to 9. In this embodiment, the system 1 includes a set of cubic modules 3 that are arranged and stacked on a base 5 in a first configuration to perform a first operation or set of operations on one or more workpieces 7.

[0111] The modules 3 can then be removed, rearranged or redeployed and new modules 3 be included to arrange and stack the modules 3 on the base 5 in a second configuration to perform a second operation or set of operations on the same workpiece(s) 7, or one or more new workpieces 7.

[0112] Any number of different configurations can be formed by different arrangements of modules 3.

[0113] Figure 1A illustrates the base 5 of the first embodiment in more detail. Figure 1A shows only a portion of the base 5. It will be appreciated that the base 5 may extend over as large an area as needed.

[0114] In the current embodiment, the base 5 is formed in polymer concrete. A plurality of base anchor points 9 are formed in a two-dimensional square array 11 on the top surface 13 of the base 5, with anchor points 9 at each node.

[0115] As show in Figures 2A and 2B, each anchor point 9 is formed with a planar surface 15 raised above the top surface 13 of the base 5. Five locator points 17a-e are formed in a quincunx shape, projecting further above the planar surface 15.

[0116] As will be discussed below in more detail, when a cubic module 3 is mounted on the base 5, each corner 19a-d of the lower face 21 of the cube is fitted on a single locator point 17a-e of an anchor point 9. The four corners 19a-f of the cube is mounted on different anchor points 9. Figure IB illustrates an example of a number of modules 3 positioned on the base.

[0117] In the current embodiment, each locator point 17a-e also includes a connector 23a-e. The connector 23a-e provides a path along which power and various different media can be conveyed between the base 5 and the modules 3.

[0118] Conduits 25a, b,c are cast into the base 5 to connect power and media from a power source 27 and media sources 29a, b to each anchor point 9.

[0119] Figure 3 schematically illustrates the basic structure of each of the cubic modules 3 in the first embodiment. Each module 3 generally includes a frame 31 having members extending along the edges of the cube. The cube has a lower face 21, an opposing upper face 33 and four side faces 35-d extending between the upper and lower faces.

[0120] Two bracing members 37a, b are provided extending between diagonally opposite corners on opposite side faces 35b, 33d.

[0121] As discussed above, on the lower face 21 of each module 3, location formations (not shown) are provided at each corner 19a-d to enable the module 3 to be positioned on the locator points 17a-e of the anchor points 9 in the base 5. As with the locator points 17a-e on the base 5, the location formations on the lower face 21 of the module 3 includes a connector (not shown) to connect to the connectors 23 in the base 5.

[0122] Inside the cube, along at least one of the vertical members 39a-d of the frame 31, conduits 41 are provided to convey power and / or media to or from the components of the module 3.

[0123] On the top face 33 of each module 3, an anchor point 43a-d is provided at each corner. The anchor points 43a-d in the top face of the module 3 are similar in arrangement to a locator point 17a-e of an anchor point 9 on the base 5. Therefore, it is possible for modules 3 to be stacked on top of each other rather than on the base 5.

[0124] As with the location points 17a-e on the base 5, a connector 45 a-d is formed in the anchor points 43a-d in the top 33 of each module 3, to allow power and / or media to be conveyed to / from modules 3 mounted on top of other modules 3.

[0125] The majority of modules 3 in the system have a standard size (for example 1 metre by 1 metre by 1 metre). In the embodiment being described, the periodicity of the grid forming the array 11 of anchor points 9 on the base 5 is half the standard size of the modules 3. This allows for greater flexibility in the positioning of the modules 3 on the base.

[0126] The modules 3 can be positioned on the base 5 and on each other by means of an overhand gantry system 47 as shown schematically in Figure 4. The overhead gantry system 47 is provided above the base 5. In one example, it includes a cross piece 49 extending across the width of the base 5. The cross piece 49 is supported on rails 51a,b at its ends, the rails 51a,b extending along the length of the base 5.

[0127] A crane 53 extends vertically downward from the cross piece 49. The crane 53 includes a clamping mechanism 55 arranged to pick up the modules 3. The clamping mechanism 8 may lift the modules 3 using the anchor points 43 on the modules 43 or by any other suitable means. In the preferred embodiment the crane 53 is capable of operating autonomously.

[0128] The crane 53 is able to move vertically (z-direction) to lift and drop the modules 3. The crane 53 is able to move along the length of the cross piece 49 between the rails 51a,b (y-direction) and the cross piece 49 is able to move along the length of the rails 51a,b (x-direction). In this way, the modules 3 can be moved across the base 5.

[0129] In use, the crane 53 moves a module 3 into approximately the correct x-y position over the base 5, and then lowers the module 3 onto the base anchor point 9.

[0130] Each connector 23, 45 includes a plurality of conduits for conveying power and other media separately, without them being mixed together. The process of connecting the module 3 to the base 5 aligns corresponding conduits in the two connectors 23, 45 to allow connection between the conduits to be formed.

[0131] Each locator point 17 may optionally include guide features (positioning formations) such as tapered sides or the like (not shown) to move the module 3 into the correct position over the locator point 17 and to align the connectors 23, 45, as the module is lowered. Furthermore, as the module 3 is lowered, the connectors 23, 45 on the base 5 and module 3 engage.

[0132] In one example, one of the connectors 23, 45 (either on the base 5 on the lower face 21 of the module 3) includes a plunger or other projection and the other connector 23, 45 includes a corresponding opening (opening).

[0133] In a first step, an initial coarse fit is established between the plunger and the opening. The connectors are then brought into alignment in a second docking step. The second docking step may be actuated by convenient energy supply including but not limited to pneumatic, hydraulic, mechanical, or electrical actuation.

[0134] A clamping system (not shown) may be provided in the base 5 and / or modules 3 in order to secure the modules 3 in place once they are located in place. The clamping system may be formed on the anchor points 9 or away from the anchor points 9. Any suitable remotely operated clamping system may be used. In one example, zero point clamps, operated pneumatically, may be used.

[0135] The engagement of the clamps may be triggered simultaneously to the second docking step. Alternatively, engagement of the clamps may trigger or be triggered by the second docking step, or may be separate from the docking.

[0136] It will be appreciated that the compressed air supply for operating, for example, the second docking step and / or clamps may be provided through the conduits 25 formed in the base 5, or may be provided separately.

[0137] The clamps may also be used to provide clamping between horizontally adjacent modules, to provide greater stiffness through the system.

[0138] One or both of the connectors 23, 45 may include a cover 57 to protect the conduits 25, 41 against ingress when they are not connected. Figure 2A shows the cover 57 in place for one connector 23b (top right hand corner).

[0139] The cover 57 may comprise a closure moveable in a track or pivotable about a pivot point to close the openings into the conduits. Alternative means of providing a closure may be readily envisaged by the skilled person. The second docking step may also actuate removal of the covers. Alternatively, a further step of removing the covers may be provided. Again, this may be remotely controlled electronically or pneumatically, or by other suitable control means.

[0140] The modules 3 and 5 include an alignment system to allow the position and relative alignment of the modules 3 to be determined in a global co-ordinate system. In one embodiment, the alignment system uses laser triangulation to determine the position of each module 3. For example, each module 3 may have one or more laser targets 59 and one or more laser emitters 61 may be provided in fixed positions around the base 5 (for example secured to the base 5 or the structure to which the base 5 is mounted).

[0141] Whilst the laser targets 59 are shown in midway along the horizontal edges of the module frame 31, it will be appreciated they may be placed at any suitable position. For example, targets 59 may be placed at the corners and extremes of modules 3.

[0142] By triangulating to the laser targets 59, the position of the modules 3 can be determined to the desired accuracy, using a module positioning sub-system.

[0143] Each module 3 will have an identifier that is unique within the set being used in a single system 1. The identifier allows the modules 3 to be differentiated and their positions to be determined. In one example, the identifier may be encoded into the target, such that the identifier can be read as a modulation or other variation in the reflected laser light. In other examples, the identifier may be read separately (for example using a QR code, RFID or the like) by a reader on the overhead gantry system 47 or another system. The approximate position of the identifier may be known from where it is read, and then the alignment system can be used to determine the position of the module 3.

[0144] It will be appreciated that whilst the modules 3 are intended to be cubic in the current embodiment, there may be deformation from this shape. This may be a permanent deformation due to, for example, drift or strain beyond the elastic recovery of the module during usage, or manufacturing defects. Alternatively, the deformation may be temporary due to, for example, loads applied, environmental conditions or the like.

[0145] Where the module 3 is provided with multiple laser targets, the deviation of the shape can also be measured by a module shape alignment sub-system. The module alignment sub-system may measure the module shape in situ on the base, or in a separate location provided for this purpose.

[0146] The module alignment sub-system may also determine and calibrate a working volume of the module 3 (the area over which a tool in the module moves). The motion of a tool in the module 3 can also be mapped and calibrated to ensure accurate positioning. Where the module is not the expected shape, the travel of the tool may be limited or modified to ensure the working volume does match the expected shape.

[0147] In some cases, the measurement of the module 3 may include measurement under a test load.

[0148] It will be appreciated that the base 5 may be considered fixed in the global co-ordinate system. However, in other examples, there may be structural deformations or drift in the base in a similar manner to the modules 3. It may be that at least some of the anchor points 9 in the base 5 are also provided with laser targets 59 for positioning in the global co-ordinate system.

[0149] As will be discussed in more detail below, depending on the precision required by the particular operation being performed, it may be necessary to know the position of the modules 3 and workpiece 7 with different degrees of accuracy. The alignment system provides for the accurate placement and localisation of the modules 3 in the global coordinate system.

[0150] Various different functions and operations can be performed by the modules 3. Figure 5 shows an example of a first type of module 3a. This module 3a is a processing module. The module 3a has a processing head 63 mounted in a clamping mechanism 65.

[0151] The processing head 63 is fed with power and / or media through a flexible hose 65a that is fed by the conduits 41 of the module 3a, and / or may be supplied using a supply module mounted in tandem with the processing module 3a.

[0152] The processing module 3a includes a first carriage 67 arranged to move on a support 69. The support 69 is able to slide on a pair of rails 71a,b on opposite sides of the module 3a, in an x direction. The carriage 67 is moveable on the support 69 in a y direction. The carriage 67 is also movable in a z direction between the support 69 and the work piece 7.

[0153] The processing head 63 may perform a variety of different operations including adding, modifying or removing material from the workpiece 7. The processing head 63 may be interchangeable with other processing and machining heads as described in WO 2014 / 013247, W02015 / 189600 and WO 2018 / 172774.

[0154] Furthermore, two or more heads may be provided in a single module to perform two operations that are the same or similar, at different points on the workpiece 7.

[0155] In the example shown in Figure 5, the processing head 63 projects downwards, such that the processing module 3a is arranged to process a workpiece 7 provided below the module 3a.

[0156] A second module 3, referred to as an environmental module 3b, can support the processing module 3a, and the workpiece 7 in an arrangement that allows the processing module 3a to access and process the workpiece 7.

[0157] Figure 6 schematically illustrates the processing module 3a mounted on a base or environmental module 3b.

[0158] The base module 3b includes a platform 73 which holds a workpiece 7. In use, the processing head 63 is brought to the workpiece 7 and moved over the workpiece 7 by the carriage 67 and support 69.

[0159] The platform 73 may be arranged to move the workpiece 7 in one or more axes to increase the degrees of freedom of the operations performed by the processing module 3a. As discussed above, the processing module 3a may move the processing head in the x, y and z directions. The platform 73 may rotate the workpiece about one or more axes in addition to this, to provide up to six degrees of freedom, overall.

[0160] In order to process the workpiece 7, the position of the workpiece 7 relative to at least the processing module 3a may be required.

[0161] In one example, the position of the workpiece 7 is inferred. It is known how the two modules 3a, 3b are positioned relative to each other, and it is known where the workpiece 7 is held in the module. Therefore, the position of the workpiece 7 is known. In other examples, the alignment system may include a workpiece alignment sub-system that determines the position of the workpiece 7 and / or processing head 63 in a local coordinate system defined by the processing module 3a. For example, the processing module 3a may include touch probes, scanners, laser emitters or the like and the processing 63, and / or platform 73 and / or workpiece 7 may include features, fiducials, and / or targets 59 to allow the position to be determined.

[0162] It will be appreciated that the position of the workpiece 7 in the global co-ordinate system can also be determined, either by transforming the local-co-ordinate system to the global co-ordinate system, or by detecting the laser targets 59 using the emitters 61 fixed with respect to the global co-ordinate system. Where the position of the workpiece 7 and / or processing head 63 / platform 73 is determined in the global co-ordinate system, the emitters 61 in the module 3a may be omitted.

[0163] Where high precision is required, a transform or shift (translation or reorientation) may be applied to the control of the movement of the processing head 63, to take into account any drift of the module shape, module placement and optionally the workpiece 7 or processing head 63 position.

[0164] In some examples, a test workpiece may be operated on, and measured, with the drift from the expected result used to apply a shift or transform to the control of the movement of the processing head 63.

[0165] In use, a three dimensional tool path is determined by a CAD / CAM or other suitable design programme. The tool path assumes an ideal system without loading. The transform or shift can then be applied to the tool path. The CAD / CAM and shift may also control (and modify) energy levels, applied, and other factors of tool operation.

[0166] The transform or shift may vary as a function of time, as different parts of the workpiece are operated on, as different functions performed, and as the system is reconfigured.

[0167] The arrangement and modules 3a, 3b shown in Figures 5 and 6 allows for processing of a workpiece 7 below the processing module 3a. It will be appreciated that simply changing the direction of the support 69, rails 71a,b and carriage 67 would allow for processing to the side of or above the processing module 3a. Figure 7 illustrates an arrangement of two processing modules 3a, 3c around a workpiece 7, to illustrate multi-point processing.

[0168] In the example shown in Figure 7, a first processing module 3a is in the same orientation as in Figure 6, and is arranged to process below the module 3a. A second processing module 3c is arranged to process to its side.

[0169] In Figure 7, the base module 3b including a platform 73 is replaced with a first spacer module 3d that increases the height at which the first processing module 3a is held, to allow a larger workpiece 7 to be processed. The first spacer module 3d is double the unit height of the arrangement.

[0170] The second processing module 3c is also secured on a spacer module 3e. However, the spacer module 3e supporting the second processing module 3c is half the unit height. This allows the second processing module 3c to access the top part of the side face of the workpiece. If the second processing module 3c needs to process the lower part of the workpiece 7, the second spacer module 3e is removed.

[0171] Moving a module 3 to access a different portion of the workpiece 7 may be referred to as analogous to a “pixel shift” camera operation and similarly is used to improve resolution and access to the parts being made in this case.

[0172] In the example shown in Figure 7, the workpiece 7 is not held on a platform 73, and is instead provided on the base 5. A planar workpiece interface (not shown) may be provided to hold the workpiece 7 in place. Alternatively, one or more of the processing modules 3a, 3c or spacer modules 3d, 3e may be secured to the workpiece 7, as will be discussed below in more detail.

[0173] In the above, processing modules 3a, 3c, base platform modules 3b, and spacer modules 3d, 3e are disclosed.

[0174] Processing modules 3a, 3c are just one example of active modules that interact directly with the workpiece 7 to perform various operations. This may include adding of material; adding of energy; removal of material; removal of energy; modifying an existing material; inspection of the workpiece; and drilling and / or tapping.

[0175] The active module 3 may comprise various tools (interchangeable or fixed) to perform the different functions. In one example, the tools may be in the form of processing or machining heads 63 in a processing module 3a, 3c as discussed above. In other examples, the tool may be a tool of a robot arm / module, or any other type of module with a tool.

[0176] In any type of active module, the tool may be moveable in one or more axes - for example, one, two, three, four, five or six axes.

[0177] The base platform module 3b, is just one example of an environmental module. Environmental modules may be arranged to hold, fix, control, modify, or otherwise interact with the environment around the workpiece 7 or the workpiece itself.

[0178] For example, the environmental modules may hold or support the workpiece; move the workpiece in one or more axes; cool the workpiece and / or the environment around the workpiece; heat the workpiece and / or the environment around the workpiece; provide an inert or reactive environment around the workpiece; and extract or remove waste material, media or conditions generated in processing the workpiece 7. Environmental modules may do more than one of the above actions simultaneously.

[0179] The environmental modules may support further modules and provide power and / or media to further modules of the plurality of modules.

[0180] In some examples, the environmental modules may also provide stiffness or rigidity to the workpiece or active modules (for example, by providing mass and / or anchor points for modules or the workpiece).

[0181] When the environmental module holds or supports the workpiece 7, it may also move the workpiece 7 in one or more axes. Further types of modules may also be provided. For example, as discussed above, spacer modules 3d, 3e may be provided for supporting additional modules and / or pixel shift operations.

[0182] Walkway modules may be provided to allow human operators to move around the modules 3 in designated areas.

[0183] As discussed above, any type of module 3 may be secured to the workpiece 7, to hold the relative alignment of the workpiece 7 and modules 3 as constant. Any suitable securing methodology may be used. For example, magnetic forces, suction or mechanical clamping may be used.

[0184] In the above examples, the modules are cubic / cuboid. However, this is by way of example only. Some modules may have different shapes, for example, they may be any suitable shape that can fit onto the anchor points 9 of the base 5. For example, they may be triangular, arranged to fit on three anchor points.

[0185] In further examples, modules 3 may have a rectangular, hexagonal, or triangular base, and then non cuboid shapes above this.

[0186] In one example, all modules 3 may be moveable, redeployable or reconfigurable. Modules may be kept in a storage area on the base 5 or adjacent the base 5 (where the gantry 47 can access the modules 3).

[0187] In other examples, at least some of the modules 3 may be permanently or semipermanently fixed in place.

[0188] Figure 8 illustrates an example of a manufacturing system 75 formed on a base 5 using a plurality of modules 3 as discussed above.

[0189] Starting from the left hand side, a base module 77a is provided for supporting a first workpiece 79a. Above this base module 77a, an additive printing module 77b is provided for depositing material onto the first workpiece 79a. A half height spacer module 77c is provided between the base module 77a and printing module 77b. To the right of the base module 77a, a milling module 77d is provided with four milling heads 93a, 93b, 93c (the fourth milling head is not shown) arranged around opposing sides of a second workpiece 79b.

[0190] Next (in a direction from left to right), are two drilling / milling modules 77e, 77f either side of a full height spacer module 77g for holding a third workpiece 79c, larger than the first and workpieces 79a, b. the drilling modules 77e, 77f drill into opposing sides of the third workpiece 79c largely counteracting the force from each respective drilling operation.

[0191] Above the spacer module 77g is a further half height spacer module 77g supporting a printing module 77h for printing on the top of the third workpiece 79c.

[0192] To the right of the second drilling module 77f, another milling module 77i is provided, for processing on the lower part of a fourth workpiece 79d. Above this module 77i is a full height spacer module 77j to accommodate the height of the fourth workpiece 79d. Another processing module 77k is provided on the a full height spacer module 77j to process the top of the fourth workpiece 79d.

[0193] A robot arm module 77m is provided to the right of the module 77i. This includes a robot arm for bracing and processing the right face of the fourth workpiece 79d.

[0194] This arrangement is intended to be exemplary only, and just shows one possible arrangement of modules 77. In this arrangement, the workpieces 79a-d can be held in a number of different positions. The workpiece 79a-d may be moved between the different positions in a number of ways, including automated robots, overhead gantries, by the travel of the platforms 73 in the base module 77a, using forklifts / pallet jacks, or human operators.

[0195] In other examples, at least part of the system 75 may be altered around a static workpiece 79a-d by moving modules into or out of the system or to different positions in the system 75. This will be discussed in more detail below.

[0196] It will be appreciated that in some variations of the system 75 the laser alignment targets 59 on all the modules 77 may not be in direct line of sight to enough (or any) of the emitters 61. Therefore, in these cases, the position of the modules can be estimated by a dead reckoning process, using the measured position of modules 77 which can be measured, and the known module shapes.

[0197] Using the moveable modules 77, the processing of a workpiece 79a-d can be balanced, so that action or influence on one side of a workpiece 79a-d is counteracted by the action or influence on an opposing side.

[0198] The action or influence may include mechanical forces, heat, cooling, environmental conditions, chemical reactions and the like.

[0199] Balancing forces in this way reduces deformation forces and stress on the workpiece 79a-d and on the modules 77, meaning the modules 77 do not need as much reinforcement or strengthening.

[0200] In one example, the balancing force may be created by active modules on opposing sides of the workpiece 79a-d. This is illustrated by the milling module 77 d, with milling heads 93a,b,c,d (93d is not shown) on four sides of the second workpiece 79b or the drilling modules 77e,f on opposite sides of the third workpiece 79c in Figure 8.

[0201] In another example an environmental module may be positioning to provide a counteracting influence on the opposite side of a workpiece. Figure 9 illustrates an example where a first robot arm 81a from an active module is pressing against the first side 83a of a workpiece 85. A second robot arm 81b from a second active module is provided on the opposite side 83b to do the active processing of that part benefited by the counteracting force provided from 81a.

[0202] In one example, the first robot arm 81a may include a drilling tool 87 to drill into the workpiece 85, whilst the second robot arm 81b provides an opposing mechanical force. However, this is by way of example only, and any suitable counteraction can be provided.

[0203] In the example shown in Figure 9, the tool of the second robot arm is replaced by a cube 89 with openings in the side, to provide the counteracting force, spread over the surface of the side 83b of the workpiece 85. Any suitable tool may be used to provide passive balancing forces.

[0204] The use of robot arms for applying this type of counteracting force is by way of example only. Various different types of modules 3 may be used in this way.

[0205] The balancing of forces may be achieved by multiple tools within a single module, or by multiple modules arranged around a workpiece. Whilst in some examples, balancing forces are arranged in pairs, the forces may be arranged at any number of points around a workpiece.

[0206] Different methods of manufacturing or processing articles using a metamorphic manufacturing system such as described above will now be discussed, with reference to Figure 10 to 12.

[0207] In any of the methods discussed below, the modules 3, 77 are initially arranged in a first configuration. As discussed below, the first configuration may be to perform a first process, or a first portion of a process.

[0208] Depending on the tolerances of the operation(s) being performed, a calibration may be performed, using the alignment system discussed above, whenever the modules are placed in a new configuration.

[0209] The process of positioning 100 the modules 3, 77 in a particular configuration is shown in Figure 10. In a first step 102, the modules 3, 77 are positioned as required.

[0210] After the modules 3, 77 are provided in place, it may be that the tolerances of the operations to be performed are such that the initial placement of the modules 3, 77 is sufficiently accurate that no further fine alignment or calibration process is required. If this is the case, then operations may be started 104 using the modules 3, 77 (via path Al).

[0211] As discussed above, the alignment system monitors the deviation of the modules 3, 77 away from their desired shape. It may be that a measurement occurs for each module 3, 75 each time it is used. Alternatively, modules 3, 75 may undergo periodic measurement during use.

[0212] Optionally, the deviation of the module shapes may be incorporated as an offset in step 106, prior to operations being started (via path A2), without other measurements being taken. This may occur if, for example, the accuracy by the simple positing is close to providing the desired tolerances.

[0213] In other cases, where greater precision is needed, a calibration process 108 may be performed (via path A3).

[0214] In the calibration process 108, a measurement of the position of the modules is taken using the alignment system at step 110, once the modules 3, 77 are arranged in their configuration.

[0215] In one embodiment (path B l in Figure 10), this measurement may simply be used to determine the offset applied during control of the operations.

[0216] In another embodiment (path B2 in Figure 10), a test workpiece may be processed and measured, on the modules 3 or separately, at step 112. The measurement of the test workpiece may be used with the measurement of the module positions to refine the offset (path Cl in Figure 10).

[0217] In a further embodiment, the position of the modules 3, 77 may be adjusted in step 114 (path C2 in Figure 10) based on the test workpiece and the measured alignment of the modules 3, 77. In one example of this embodiment (path DI in Figure 10), the offset may be determined after the adjustment step 114. In another example (path D2 in Figure 10), the method may loop back to the step 110 of measuring the position of the modules 3, 77.

[0218] It will be appreciated that the choice of paths (Bl vs B2, Cl vs C2) may be automatic. On the other hand, a check may be carried out to determine if the measured position of the modules 3, 77 or the accuracy of the test workpiece meets a sufficient threshold for the accuracy required by the operations to be performed. If the accuracy threshold is not met, the process may repeat the steps of measuring 110, processing a test piece 112 and adjusting the modules 114 to a finer degree of accuracy.

[0219] It may be that after the loop is repeated a fixed number of times (one or more repetitions), the check step(s) is removed, the process automatically determining the offset. Alternatively, if the threshold cannot be reached during a certain number of loops, an error may be returned to indicate that the required accuracy cannot be reached.

[0220] As shown in Figure 10, the step 112 of making the test piece 112 can be omitted (path B3). This may be in some or all of the loops, even if the process is not repeated iteratively.

[0221] Figure 11 illustrates a first method 200 of performing operations on a workpiece.

[0222] In the method 200 of Figure 11, the processing or manufacturing comprises a number of different stages. The method 200 includes a first step 202 of arranging the modules in a first configuration. The first configuration comprises modules arranged to perform at least two stages of the processing or manufacturing. The first stages of the processing or manufacturing then occurs at a next step 204.

[0223] In a further step 206, the modules are arranged in a second configuration arranged to perform later stages of the process at step 208. This process of rearranging the modules 3, 77 is repeated until the processing or manufacturing is completed.

[0224] In this embodiment, the different stages that are completed within a single configuration of the modules may be performed at different physical locations within the arrangement of modules 3, 77. In this example, the workpiece may be moved between the different locations, to complete the different stages, as discussed above.

[0225] It may be that when the modules are rearranged 206, the workpiece is moved to a storage location. Alternatively, the module / location where the workpiece is held in the last stage of the first configuration may be retained whilst the other modules are being moved for the next configuration. In a specific example of this it may be that whilst a current stage is being performed, the modules from a previous stage are being moved and arranged to perform a next stage. In this way, the process or manufacturing can occur continuously, with limited numbers of modules used and limited space taken up at any given time. This may be seen as similar to moving a heavy item on rollers, and moving rollers from behind the item to in front of it, as it is moved.

[0226] Figure 12 shows an alternative method 300 of processing or manufacturing a workpiece. In this method 300, the modules 3, 77 are again setup in a first configuration in a first step 302. In this example, the first stage (or stages) of processing are performed at a second step 304 without moving the workpiece or modules.

[0227] In a third step 306 of the method 300, the modules 3, 77 are rearranged around the workpiece, to perform the next stages. This may simply involve rearranging the existing modules 3, 77 or it may involve removing some modules 3, 77 and adding new modules 3, 77.

[0228] These steps may be repeated until the manufacturing or processing is complete.

[0229] In some examples of this method, the modules 3, 77 for different configurations are located at the same place. In other examples, the different configurations may involve moving the modules around a large stationary workpiece, to operate on different parts of the workpiece. Therefore different stages of the operation may be considered to be doing similar operations at different locations or doing the different operations at single location, or a mixture of both. This provides significant flexibility in processing larger workpieces. The arrangement of modules 3, 77 around a large scale workpiece such as an airplane fuselage or wing, or wind turbine would look similar to the covering of the side of a building with scaffolding.

[0230] In the above example, the process is arranged to manufacture or process one item (or a plurality of similar items). However, it will be appreciated that either method may also include the step of arranging the modules in further configurations to perform completely different processes. In the above examples, one stage is performed at a time. However, it will be appreciated that the processing or manufacturing may be parallelised at various stages. For example, a first workpiece may be undergoing a first operation at one location, and a second workpiece may be undergoing a different operation at a different location, within the same system. This therefore increases throughput of the system.

[0231] Where a process only includes a single stage, the configuration of the modules is arranged to perform the single step.

[0232] In the examples discussed above, the calibration occurs before any processing or manufacturing takes place. In further examples, the processing head and workpiece may be continually tracked during processing or manufacture. Optionally, the deformation / position of the modules and the working volume and tool movement may also be tracked during operation. This may provide dynamic updates to the transform / shift applied to control the modules. For example, this may take into account changes when under high loads.

[0233] In further examples, the calibration / alignment may be checked at various intermediate stages. For example, after each stage or individual operation. In one example, where a plurality of holes are drilled (or other operations are repeated a number of times) the calibration and alignment may be repeated after each operation / action.

[0234] It will be appreciated that the methods 200, 300 presented in Figures 11 and 12 are just two examples. In various other embodiments, the process may be a hybrid of the two examples. For example, some stages may be performed as in the first method 200 in Figure 11, and further stages may be performed as in the second method in Figure 12.

[0235] The methods and processes discussed above (both the arrangement 100 of the modules and the processing or manufacturing 200, 300) are carried out under a controller 91. Data communication between the modules 3, 77 and the system controller 91 may be through data connections provided along with the power and media connections.

[0236] As discussed above, each module 3, 77 has a unique identifier. This may also be used to allow all modules to be addressed on a single communications channel (for example using serial communication standards and the like). In one example, modules with moveable / controllable functions may have a local (follower) control that is controlled by the system controller (leader) 91. However, in other examples, a single system controller may be the only controller. The system controller 91 may therefore directly control the tools and other moveable / controllable functions.

[0237] The controller may be arranged to avoid collision of different tools / modules / workpieces as they are moved. It may also be arranged to optimise multiple tool paths for parallel processing.

[0238] The controller 91 may provide augmented reality or virtual reality outputs, to allow operators to interact with the system.

[0239] Environmental sensors (temperature, humidity and the like) may also be provided to monitor the external environment. Optionally, these may influence the transform or shift applied by the controller 91 to the tool path.

[0240] The modules 3, 77 discussed above are given by way of example only.

[0241] The modules 3, 77 (and hence the grid for the modules 3 and base 5) may be any suitable shape. For example, the modules 3, 77 may be spherical, spheroid, cubic, cuboid, cylindrical, hexagonal prisms, cones, square based pyramids, tetrahedrons, triangular based pyramids, regular or irregular pyramids, triangular prisms, paraboloids, polyhedrons, convex polyhedrons, concave polyhedrons, or polyhedroids (regular or irregular), platonic solids (including but not limited to octahedron, dodecahedron, icosahedron, etc.), torus, toroid, thor, ellipsoid, extruded hexagonal prism, hyperboloid, any revolute volume, or any other segment, truncation, or reduced from nominal working volume, any section of any of the above, or other shapes appropriate for the intended function. Furthermore these modules may house additional types of motion platforms or additional equipment including: various styles of robots, parallel kinematic motion platforms, etc.

[0242] Furthermore, whilst the modules 3, 77 discussed above are Im by Im by Im, any suitable size may be used. In the examples discussed above, conduits are provided at each corner of the modules 3, 77. However, this need not be the case, and conduits may be provided at three or fewer corners.

[0243] In additional, or alternatively, conduits and connectors may be provided away from the corners of the modules, either along the edges faces of the module 3, 77 within the volume of the module, or adjacent to the module 3,77. In this case, the connectors 23 in the base 5 may be away from the locator points 17, and connect separately. In further examples, a separate connector device may be provided to connect between the connectors in the base 5 and the connectors for the module. In one example, the connectors may be provided in the clamping system.

[0244] Figures 13A and 13B illustrate an alternative method of forming connections to the modules 3,77. In this example, the module 3, 77 is as described above unless explained otherwise.

[0245] The module 3 shown in Figures 13A and 13B has a frame 31 as described above. The module 3 in Figures 13A and 13B is provided on the base 5. The module 3 is located on and secured to the base 5 through anchor points 9 having locator points 17. As discussed above, the modules 3, 77 may be secured to the base 5 in a single stage process or two stage process, with coarse and fine alignment.

[0246] In the examples shown in Figure 3, a capstan device 101 is provided on the base, located centrally with respect to the module 3, 77. The capstan device 101 has a central hub 103 and four arms 105a-d extending out form the hub 103. The arms 105a-d have downward extending projections 107a-d formed at the ends opposite the hub 103.

[0247] The connections for media, power and data are formed in the hub 103 and conduits extend along the arms 105a-d to connectors (not shown) formed in the projections 107a- d.

[0248] The arms 105a-d are configured to lift and rotate relative to the hub 103. The person skilled in the art will appreciate various methods of creating connectors that can move and rotate or slide into position as required. In Figure 13A, the module 3, 77 on the base 5. The arms 105a-d are rotated such that they extend between diagonally opposite corners of the module 3. The projections 107a- d rest on the floor to protect the connectors.

[0249] Once the module 3 is located, the arms are lifted are rotated by 45 degrees so that they extend over horizontal members 109a-d of the frame 31. The arms 105a-d are then lowered onto the horizontal members 109a-d.

[0250] Lowering the arms 150a-d onto the horizontal members 109a-d has two effects. Firstly, the connectors formed in the projections 107a-d engage with corresponding connectors (not shown) in the horizontal members 109a-d to form connections for delivering power and media (and optionally data). Secondly, the downward force of the arms acts as the clamping mechanism to hold the module 3 in place.

[0251] The connectors for media and data are formed in the same way as described above.

[0252] In a system with stacked modules 3, 77 modules located on the base 5 may have connections for media and power formed by a capstan device 101, and the modules located on top of other modules may be connected at the corners of the modules 3, as discussed in previous embodiments. Alternatively, a capstan device may be provided on the top face of lower modules.

[0253] The capstan device 101 illustrated in Figures 13A and 13B has four evenly spaced arms of equal length. However, this is by way of example only. There may be any number of arms of different lengths. Furthermore additional arms may also provide protection for any areas that should not exposed.

[0254] Furthermore, in some cases, the capstan device 101 may be used for connectivity of media and power only, with a separate clamping mechanism provided for holding the modules in place. Alternatively, there may be no clamping mechanism,

[0255] In other examples, the capstan device 101 may be used for clamping only. The connectivity of media may be through any other means, such as the embodiments discussed above, or connectivity may not be provided. The capstan device may be used to hold the modules in place and provide connectivity in any modular system. It may be used in the systems described herein or in any other type of system requiring connective of power and / or media and optionally clamping.

[0256] The final position of the capstan may also be used as an indicator for alignment by using sensors, camera vision, or other detection equipment.

[0257] In some examples, such as discussed above, a standard size module may locate on base locator points 17 at its corners, and may also overlie additional locator points. The locator points away from the edge may be used for additional location function and / or for connectivity of power and / or media.

[0258] In the examples discussed above, all conduits are provided in a single location. However, it will be appreciated that conduits for different media and / or power may be provided at different locations in the module 3, 77.

[0259] The module 3, 77 may have any suitable structure, depending on its uses. The material, and thickness of the frame may be chosen depending on the desired strength and rigidity of the module. For example, where a lightweight module is possible, aluminium may be used, whilst steel may be used in heavier modules. Any number of bracing members and any shape of frame may be used.

[0260] In some examples, the conduits may be routed through the members forming the frame. In other examples, they may be separate.

[0261] It will be appreciated that the identifiers used in the positioning system may be the same or different to the identifiers used in control / communications system.

[0262] The base 5 discussed above is also given by way of example only. Any suitable material may be used for the base 5.

[0263] Furthermore, any suitable arrangement of anchor points 9 may be used. In the above examples, the anchor points project above the base surface, but this is by way of example only. They may be flush with the base 5 or recessed into it. In some cases, anchor points for a polar arrangement of modules may be provided in addition to or instead of the square grid.

[0264] In the above examples, the location and connector functions are located together, but this need not be the case, and the locators and connectors may be located separately.

[0265] In some examples, at least some of the power and / or media connections may be routed from above, or beside the modules, rather than below.

[0266] In the example shown in Figure 4, the conduits are routed in rows, and along one column. This is by way of example only, and the conduits may follow any path.

[0267] In the above examples, the spacing of the anchor points 9 on the base is at 0.5 of the standard unit size. This is by way of example only, the spacing may be any fraction or multiple of the unit size, or a single integer of the unit size.

[0268] It will be appreciated that the arrangement of the anchor points will be varied correspondingly with the shape of the modules 3, 77.

[0269] It will be appreciated that in some cases, the modules may be arranged without being located on the base 5. In this case, the modules may be secured together or may be directly attached to a large part or arranged in some other way. In this case, supply of media and power may be installed separately, or modules may be provided to function as media and power sources. Supplies may be provided to the base of the modules 3 using cables, tubes, wires, pipes, and the like

[0270] Where the modules 3, 77 are arranged without using a base 5, they may only be located with respect to each other, and the global co-ordinate system will be established independent of any specific base 5.

[0271] Arranging the modules 3 without using a base 5 may result in a lower rigidity and lower initial system alignment precision. In this case, the forces and speed of the modules would be adjusted to keep within the required range of positional accuracy and rigidity for the workpieces. In the above examples, a gantry system 47 is provided to move the modules. This is provided by way of example only. Any suitable movement method may be used, and the modules may be moved in any direction or orientation in any way.

[0272] The modules may also be moved in different ways, other than by gantry. For example, modules may be moved by automatically guided vehicles, AGVs; forklift; automated robots; drones; movement systems formed in the modules; and manually by operators. It will be further appreciated that in any given system, multiple different ways to move modules may be provided. For example, modules 3, 77 may be moved out of a storage area by forklift, or robot, and then moved into position on the base by overhead gantry.

[0273] The connections for power and / or media supply are given by way of example only. Any suitable connector may be used, with covers for protecting against ingress into the conduits.

[0274] In the above example, a single cover protects all conduits. However, this is by way of example only and any suitable cover or covers may be used.

[0275] In the above example, zero point clamps are used to secure the modules 3, 77 to the base 5 and each other. This is by way of example only, and any suitable clamping means may be used. For example, the modules may be screwed, bolted, riveted, bonded, friction stir bonded, and the like. Modules may also be held my magnetic forces, suction, cables and ropes (including support from above). For moveable modules, this clamping may be performed by an automated robot, or an operator. Modules may also be used while in motion provided by a track, robot, or other movement vehicle.

[0276] External scaffolding and braces may also be applied, and internal bracing may also be applied, within the modules. Some of the bracing may be expandable or configured to be engaged and disengaged (for example pneumatic rods).

[0277] Automated robots may also be used for bracing or to clamp modules in place.

[0278] In the examples discussed above, laser positioning is used to determine the locations of the modules. In other examples, any other suitable positioning system with sufficient accuracy may be used. Where the system uses emitters and targets / receivers, either one of the targets or emitters may be arranged on the modules 3, 77 with the other being fixed with reference to the global co-ordinate system.

[0279] Any suitable type of power source may be used. The power source may be a connection to a mains supply, generator, transformer, battery or other storage means or the like.

[0280] The media may fall into a number of categories. For example, there may be processable media that is added to and / or removed from the workpiece. There may also be process assist media, such as heating / cooling media, shield media, containment media, lubrication media, energy, and air or oil for operation or pneumatic / hydraulic parts. There may also be environmental media for creating an inert or reactive environment around the workpiece 7.

[0281] The media may also be a transmission mechanism for heating cooling, or other effects.

[0282] Where the media comprises energy, this may be, for example, laser or other forms of light. In this case, the conduits may comprise optical fibres, or other arrangements to permit transmission of electromagnetic energy.

[0283] Any suitable source or reservoir may be used. In some cases, the modules 3, 77 may include a small reservoir that can be filled by the conduits. In the other cases, the modules 3, 77 may comprise a larger reservoir or source that can be replenished by other means, for example operated by the gantry system.

[0284] In some embodiments the media may comprise a polymer material. In other embodiments the media may be selected from a group comprising metals, non-metals, polymers, ceramics, clay, composites or dielectric materials. The media may be provided in any of the following forms: in powder form; filaments, rods, pellets, sheets or wires, or in semi- to fully liquid form. Alternatively media can be provided as, or in suspension in, a liquid, emulsion, gas, aerosol, slurry or paste.

Claims

CLAIMS1. A system for processing or manufacturing a workpiece, the system comprising a plurality of moveable modules having: anchor points for locating the plurality of moveable modules to each other and / or a support surface; module connectors arranged to convey media and / or power and / or data between adjacent modules and / or the support surface; and at least some of the plurality of modules having tools for interacting with the workpiece, wherein the modules are moveable and interchangeable to vary processing and manufacturing steps performed on a workpiece.

2. The system of claim 1, also including an alignment system configured to determine a relative alignment between the plurality of modules and the workpiece.

3. The system of claim 2, wherein the alignment system includes one or more of: a module shape alignment sub-system configured to determine the deviation of each module from an expected shape and / or the deviation of tool movement in the module from an expected path; a module position alignment sub-system configured to determine a position of each module in a global co-ordinate system; and a workpiece alignment sub-system configured to determine the position of the workpiece in the global co-ordinate system.

4. The system of claim 2 or claim 3, wherein the alignment system is configured to at least in part control movement of the tools based on the determined relative alignment between the modules and the existing or intended workpiece, wherein the alignment system controls movement of the tools based on an expected alignment determined from an expected and ideal placement of the modules and shape of the modules, and an adjustment to best match the ideal placement and shape determined by the alignment system.

5. The system of any of claims 2 to 4, wherein the alignment system is configured to control the tool, at least in part, based on any adjustments determined by analysis of a previous workpiece processed by the system.

6. The system of any of claim 2 to 5, wherein the alignment system is configured to track the position of the tools relative to the workpiece and modules, during use.

7. The system of any preceding claim wherein the plurality of modules includes a set of active modules, the active modules including tools for performing operations on the workpiece.

8. The system of claim 7, wherein the operations include: adding of material; adding of energy; removal of material; removal of energy; modifying an existing material; inspection of the workpiece; and drilling and / or tapping.

9. The system of claim 7 or 8, wherein at least some of the active modules comprise processing modules, wherein in the processing modules, the tool comprises at least one processing or machining head arranged to add, modify or remove material from the workpiece.

10. The system of any of claims 7 to 9 wherein at least some of the active modules comprise robot modules comprising tools held and moved by a robot arm.

11. The system of claim 9 or claim 10, wherein the tool is interchangeable.

12. The system of any of claims 7 to 11 wherein the tool is moveable in one, two, or three, or more axes, relative to the workpiece.

13. The system of any of claims 7 to 12, wherein the system is arranged to position at least two active modules at opposing positions around the workpiece, such that when the active modules perform operations on the workpiece, the actions from different modules on the workpiece at least part counteract each other.

14. The system of claim 13, wherein the actions that at least in part counteract each other comprises one or more of: applying mechanical forces to oppose mechanical forces applied by the first active module; applying heat to oppose heat or cooling applied by the first active module; applying cooling to oppose heat or cooling applied by the first active module; and invoking environmental conditions to counteract the influence of the first active module; and causing or inhibiting chemical or physics-driven reactions to counteract any influence by the first active module or the processing thereby.

15. The system of any preceding claim, wherein the plurality of modules comprises a set of environmental modules, the environmental modules arranged to perform one or more of the following: support further modules of the plurality of modules; provide power and / or media to further modules of the plurality of modules; hold or support the workpiece; move the workpiece in one or more axes; cool the workpiece and / or the environment around the workpiece; heat the workpiece and / or the environment around the workpiece; provide an inert or reactive environment around the workpiece; and extract or remove waste material, media or conditions generated in processing the workpiece.

16. The system of claim 16, when dependent on claim 12 or any claim dependent thereon, wherein when the environmental module is arranged to move theworkpiece in one or more axes, the axes the environmental module moves the workpiece in being different to the axes the tool is moveable in.

17. The system of claim 16 or claim 17, when dependent on any one of claims 7 to 14, wherein the environmental modules are arranged to at least in part counteract the actions of the active modules without performing an operation on the workpiece.

18. The system of any preceding claim, wherein the plurality of modules are arranged to process multiple points of the workpiece simultaneously.

19. The system of any preceding claims, wherein plurality of modules are moveable by one or more of: an overhead gantry system automatically guided vehicles, AGVs; forklift; automated robots; drones; movement systems formed in the modules; and manually by operators.

20. The system of any preceding claim, wherein the plurality of modules are moveable around a workpiece, to perform one or more different functions on different portions on the workpiece.

21. The system of any preceding claims, wherein the workpiece is moved between different modules, to perform a variety of functions on the workpiece.

22. The system of any preceding claim, wherein the modules are arranged with a unit size, and wherein the modules are arranged to be assembled in a three- dimensional grid or pattern having periodicity corresponding to a fraction of the unit size to allow an offset of the unit size between modules.

23. The system of claim 22, wherein the grid comprises a periodicity of half the unit size.

24. The system of claim 22 or claim 23, wherein the plurality of modules comprises a plurality of spacer modules, the plurality of spacer modules arranged to provide a shift of a multiple of one or more of the unit size between modules, a fraction of the unit size between modules, or a change of orientation of modules.

25. The system of any preceding claim, wherein at least some of the plurality of modules include a fixing system to secure the module to the workpiece.

26. The system of claim 25, wherein the fixing system uses one or more of: magnetic forces suction; and mechanical clamping.

27. The system of any preceding claim including: a base surface having a plurality of base anchor points and a plurality of base connectors through which media and / or power are conveyed.

28. The system of claim 27, when dependent on claim 3 or any claim dependent thereon, wherein the base surface is fixed in the global co-ordinate system.

29. The system of claim 27 or claim 28, when dependent on claim 22 or any claim dependent thereon, wherein a first set of base anchors including some or all of the base anchor points are arranged on a two-dimensional grid comprising a planar lattice with periodicity corresponding to a fraction of the unit size.

30. The system of claim 29, wherein the two-dimensional grid comprising a planar lattice with periodicity corresponding to a half of the unit size.

31. The system of claim 30, wherein each anchor point is arranged at a node of the two-dimensional grid, and comprises a plurality of locator points, each locator point arranged to locate a module in a different position and orientation in the two-dimensional grid.

32. The system of claim 31 wherein the locator points are arranged in a pattern that mirrors a cell of the grid.

33. The system of any of claims 30 to 32, including a second set of base anchors configured to provide a polar arrangement of the plurality of modules, each base anchor in the second set including one or more locator point.

34. The system of any of claims 31 to 33, wherein each locator point includes: a positioning formation in the base surface, arranged to engage a corresponding formation in the module.

35. The system of any of claims 31 to 34, wherein each locator point is arranged to provide mechanical alignment of the modules.

36. The system of claim 35, wherein the connectors are formed in or adjacent to the positioning formations of the locator points.

37. The system of claim 36, comprising a separate connector associated with each locator point.

38. The system of any of claims 29 to 37, wherein each base anchor includes an alignment point to determine the position of the base anchor in the global coordinate system.

39. The system of any of claims 28 to 38, wherein the base surface includes embedded conduits for conveying power and / or media to or from the base connectors.

40. The system of any preceding claim, wherein in a connection between two connectors, one or both connectors includes a cover arranged to prevent contamination of the connectors.

41. The system of claim 40, wherein the covers are opened by the process of engaging the connectors.

42. The system of any preceding claim, wherein the connectors form at least part of the anchor points.

43. The system of any of claims 1 to 41, comprising a connector device having: a hub located on the base surface; one or more arms extending radially from the hub; and conduits for power or media extending from the base surface, through the hub and the arm, wherein the one or more arms are rotatable and liftable between a first position in which the arms are disengaged with the module and a second position in which the arms engage the module to provide one or more of a connection for power and / or media and / or data and a clamping function.

44. The system of any preceding claim, wherein at least some of the modules comprise conduits for conveying power and / or media to the module connectors.

45. The system of any preceding claim, wherein control signals are delivered to the modules and / or tools through the module connectors.

46. The system of claim 45, wherein each module has a separate identifier, and wherein the control signals for the plurality of modules are delivered through a common channel, the identifiers allowing each module to be controlled independently.

47. The system of claim 45 or claim 46, comprising a single system controller for operating the plurality of modules and tools.

48. The system of any preceding claim, wherein the plurality of modules are fixed in place by zero-point clamps.

49. The system of any preceding claim, wherein the media comprises one or more of: processable or feedstock media to be added to or form the workpiece; cooling media;shielding media; heating media; containment media; lubrication media; waste or by-products; and pneumatic or hydraulic media.

50. A method of manufacturing or processing a first article using the system of any preceding claim, the method comprising: selecting at least some of the plurality of modules; locating the selected modules on the base surface or on other modules; performing at least part of the manufacturing or processing using the selected modules.

51. The method of claim 50, wherein the manufacturing or processing comprises a plurality of stages.

52. The method of claim 51, wherein selecting and locating the modules comprises selecting and locating single modules or groups of modules, each single module or group of modules corresponding to a different stage, wherein the method comprises: moving the workpiece between different modules or groups of modules to carry out different stages.

53. The method of claim 52, comprising: locating or positioning modules for later stages after earlier stages are completed.

54. The method of claim 53, comprising: removing or redeploying modules associated with stages that have been completed.

55. The method of claim 54, comprising: whilst a current stage is being carried out, locating and / or redeploying modules removed from earlier stages to carry out later stages.

56. The method of any of claims 51 to 55, wherein for at least two stages, the workpiece is kept in the same place, and the modules are moved or rearranged around the workpiece.

57. The method of claim 56, wherein the modules are moved relative to the workpiece to manufacture or process different portions of the workpiece.

58. The method of any of claims 50 to 57, comprising manufacturing or processing a second article, different to the first article, the method comprising: rearranging at least some of the plurality of modules to manufacture or process the second article.

59. The method of claim 58, wherein the modules are rearranged after the first article is complete.

60. The method of claim 58, wherein at least some of the modules are rearranged whilst the first article is being processed.

61. A base surface for forming a reconfigurable system for manufacturing or processing a workpiece, the base surface comprising: a plurality of base anchor points for locating a plurality of moveable and interchangeable modules to form the system; a plurality of base connectors arranged to convey media and / or power to and from the modules.

62. The base surface of claim 61, wherein the base surface is fixed in a global coordinate system defining the reconfigurable system for manufacturing or processing a workpiece.

63. The base surface of claim 61 or claim 62, wherein a first set of base anchors including some or all of the base anchor points are arranged on a two- dimensional grid comprising a planar lattice with periodicity corresponding to a fraction of the unit size of the modules, preferably half of the unit size of the modules.

64. The base surface of claim 63, wherein each anchor point is arranged at a node of the two-dimensional grid, and comprises a plurality of locator points, each locator point arranged to locate a module in a different position and orientation in the two-dimensional grid.

65. The base surface of claim 64 wherein the locator points are arranged in a pattern that mirrors a cell of the grid.

66. The base surface of any of claims 63 to 65, including a second set of base anchors configured to provide a polar arrangement of the modules, each base anchor in the second set including one or more locator point.

67. The base surface of any of claims 64 to 66, wherein each locator point includes: a positioning formation in the base surface, arranged to engage a corresponding formation in the module.

68. The base surface of any of claims 64 to 67, wherein each locator point is arranged to provide mechanical alignment of the modules.

69. The base surface of claim 68, wherein the connectors are formed in or adjacent to the positioning formations of the locator points.

70. The base surface of claim 69, comprising a separate connector associated with each locator point.

71. The base surface of any of claims 62 to 70, wherein each base anchor includes an alignment point to determine the position of the base anchor in the global coordinate system.

72. The base surface of any of claims 61 to 71, including embedded conduits for conveying power and / or media to or from the base connectors.

73. A module for forming a reconfigurable system for manufacturing or processing a workpiece, the module comprising:anchor points for locating the module relative to a base surface or other modules; and module connectors arranged to convey media and / or power to and / or from adjacent modules and / or the support surface; wherein the module is arranged to perform one or more functions to process or manufacture the workpiece or to enable manufacturing or processing of the workpiece and wherein the module is moveable and interchangeable to vary the functions performed on a workpiece by placing the module in different locations.

74. A module as claimed in claim 73, wherein the module is an active module including tools for performing operations on the workpiece.

75. A module as claimed in claim 74, wherein the operation is one or more of: adding of material; adding of energy; removal of material; removal of energy; modifying an existing material; inspection of the workpiece; and drilling and / or tapping.

76. A module as claimed in claim 73 or 74, wherein at the module is a processing module, the tool comprising at least one processing or machining head arranged to add, modify or remove material from the workpiece.

77. A module as claimed in claim 74 or 75, wherein at the module is a robot module comprising tools held and moved by a robot arm.

78. A module as claimed in any one of claims 74 to 77, wherein the tool is interchangeable.

79. A module as claimed in any one of claims 74 to 78 wherein the tool is moveable in one, two, or three, or more axes, relative to the workpiece.

80. A module as claimed in claim 73, wherein the module is an environmental modules arranged to perform one or more of the following: support further modules of the plurality of modules; and provide power and / or media to further modules of the plurality of modules; hold or support the workpiece; move the workpiece in one or more axes; cool the workpiece and / or the environment around the workpiece; heat the workpiece and / or the environment around the workpiece; provide an inert or reactive environment around the workpiece; and extract or remove waste material, media or conditions generated in processing the workpiece.

81. A module as claimed in claim 80, wherein when the environmental module is arranged to move the workpiece in one or more axes.

82. A module as claimed in claim 80 or claim 81, wherein the module is arranged to at least in part counteract the actions of a different active module arranged to perform an operation on the workpiece, the environmental module counteracting the actions of the active module without performing an operation on the workpiece.

83. A module as claimed in claim 73, wherein the module is a spacer module arranged to provide a shift in a plurality of modules arranged on a grid, the shift being a shift of a multiple of one or more of the unit size, a fraction of the unit size, or to provide a change of orientation of modules84. A module as claimed in any one of claims 73 to 83, wherein the module includes a fixing system to secure the module to the workpiece.

85. A module as claimed in claim 84, wherein the fixing system uses one or more of: magnetic forces suction; andmechanical clamping.

86. A module as claimed in any of claims 73 to 85, wherein the first manifold includes a cover arranged to prevent contamination of the connector.

87. A module as claimed in claim 86, wherein the cover is opened by the process of engaging the connectors.

88. A module as claimed in any of claims 73 to 87, wherein the module connector form at least part of the anchor points.

89. A module as claimed in any of claims 73 to 88, wherein the module comprises conduits for conveying power and / or media to the module connectors.

90. A module as claimed in any of claims 73 to 88, wherein control signals are delivered to the module through the module connectors.

91. A module as claimed in claim 90, wherein the module has an identifier, and wherein the control signals for a plurality of modules are delivered through a common channel, the identifier allowing the module to be controlled independently to the other modules.

92. A module as claimed in any one of claims 73 to 91, comprising zero-point clamps for securing the modules to a base surface and / or other modules.

93. A module as claimed in any one of claims 73 to 92 wherein the media comprises one or more of: processable or feedstock media to be added to or form the workpiece; cooling media; shielding media; heating media; containment media; lubrication media waste or by-products; and pneumatic or hydraulic media.

94. A connector device for use with a modular manufacturing system including a plurality of interconnecting modules, the connector device locatable on a base surface and including: a hub locatable on the base surface; one or more arms extending radially from the hub; and conduits for power or media extending from the base surface, through the hub and the arm, wherein the one or more arms are rotatable and liftable between a first position in which the arms are disengaged with the module and a second position in which the arms engage the module to provide one or more of a connection for power and / or media and / or data and a clamping function.

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