Dynamic Manufacturing Alignment Using Global and Local Metrology
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Solution Overview
Problem
Aerospace manufacturing faces challenges with robotic systems due to the need for large, expensive support fixtures and static systems that struggle with alignment and environmental variations, making them inflexible and inefficient in large, open environments.
Innovation Solution
The implementation of automated dynamic manufacturing systems that include a global metrology device, a robot with a local metrology device and end effector, and a supply of parts, using closed-loop feedback and vision systems to dynamically align and position components, allowing for flexible and precise task performance in a modular and adaptable manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If stationary support fixtures are used to ensure proper alignment, then manufacturing precision is improved, but device complexity and infrastructure requirements increase
Solution Approach 1:
The patent replaces mechanical alignment fixtures with a vision-based metrology system. The global vision system captures images of fiducial markers on the apparatus and robot, calculates pose information through coordinate transformations, and provides feedback for alignment. This substitutes the mechanical fixture system with an optical measurement and computational system, eliminating complex physical infrastructure while maintaining alignment precision.
Solution Approach 2:
The patent introduces fiducial markers as intermediary elements between the apparatus and the vision system. These markers serve as reference points that enable the global vision system to accurately track and align the robot with the apparatus without requiring direct mechanical contact or complex fixtures. The markers act as mediators that translate physical positions into measurable optical signals.
2Stability of the object's composition
If bolted fixtures are used to fix the robot in space, then stability is improved, but adaptability to environmental variations worsens
Solution Approach 1:
The patent transitions from a static, bolted fixture system to a dynamic, feedback-controlled system. The global vision system continuously monitors the positions of the apparatus and robot, and the controller adjusts the robot's position in real-time based on measured deviations. This dynamic approach maintains stability through active correction rather than passive mechanical constraint, enabling adaptation to environmental variations such as thermal expansion or vibration.
Solution Approach 2:
The patent implements a closed-loop feedback system where the global vision system measures the actual positions of the apparatus and robot, compares them to desired positions, and feeds this information back to the controller for correction. This feedback mechanism enables the system to automatically compensate for environmental variations and maintain accurate alignment without requiring rigid mechanical fixtures.
3Manufacturing precision
If large support fixtures are used in open environments, then manufacturing precision is improved, but loss of substance and waste increase
Solution Approach 1:
The patent replaces extensive mechanical support fixtures with a virtual alignment system based on vision and computation. By using the global vision system to track fiducial markers and calculate pose information, the system eliminates the need for large physical fixtures that would otherwise be required to maintain precision in open environments. This substitution reduces material consumption and waste while maintaining manufacturing precision.
4Manufacturing precision
If stationary robots are used, then manufacturing precision is improved, but productivity and flexibility worsen
Solution Approach 1:
The patent enables the robot to move dynamically throughout the assembly area while maintaining precision through continuous vision-based tracking. The global vision system monitors the robot's position and the apparatus's position independently, and the controller calculates the relative pose information in real-time. This allows the robot to access different parts of large apparatus efficiently without being constrained to a fixed location, improving productivity while maintaining task execution precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces infrastructure requirements, improves access and quality, increases flexibility and efficiency, and enhances safety and ergonomics, enabling more precise and adaptable manufacturing processes in aerospace and other large-scale applications.
Implementation Method 1
a global metrology device configured to track the positions of the apparatus, the robot, and the supply of parts using a global vision system
Implementation Method 2
a local metrology device configured to position the end effector with respect to the apparatus using a local vision system (e.g., via closed loop feedback)
Data Source
AI summary
Automated dynamic manufacturing systems may provide for alignment of multiple components with respect to one another, such as an apparatus, a robot, and a supply of parts. The alignment may initially be performed roughly, using a global metrology device configured to track the apparatus, robot, and supply of parts, each of which may be movable with respect to the others, such as by being positioned on a respective automated guided vehicle. Alignment may then be performed to closer tolerances using a local metrology device coupled to the robot and configured to accurately position an end effector, such that the end effector may perform a manufacturing task on the apparatus, such as a pick-and-place process involving transporting an individual part from the supply of parts, transferring it to the apparatus, and coupling it thereto. Such systems and methods may be used to perform manufacturing processes on large apparatus, such as aircraft.