A program evaluation device for evaluating an operation program for a robot. The operation program is a program that causes the robot to perform processing of a workpiece using a tool, and the robot has a function of correcting a position of the tool in response to an amount of wear of the tool. The program evaluation device includes an operation verification unit that verifies whether the robot will operate correctly in accordance with the operation program with each of a plurality of amounts of wear within a predetermined range.

A method and system for drilling holes in a repaired composite structure. Four corner holes are selected from holes outside of a repaired area in the repaired composite structure. The four corner holes define a rectangle encompassing the repaired area with sides that each include a pair of corner holes with intermediate holes in between. A surface representation is generated based on a scan of the repaired composite structure that includes the rectangle. Side hole locations between a corresponding pair of corner holes are generated for each side of the rectangle. Grid vector lines are generated between corresponding pairs of side hole locations on opposite sides of the rectangle. The grid vector lines intersect each other at intersection points on the surface representation. Point coordinates are determined for intersection points that lie within the repaired area. A path is created for drilling holes at point coordinates for the intersection points.

A machine comprising a frame supported on a movable carrier. A first actuator is adapted to actuate a boom coupled to the frame. A first sensor generates signals indicative of a spatial orientation of the boom. At least one second actuator actuates a drilling work device coupled to the boom. A second sensor generates signals indicative of a spatial orientation of the drilling work device. A controller receives signals indicative of the spatial orientation of the boom and the drilling work device and actuates at least one of the first actuator and the second actuator through predetermined sequential steps to automatically position the machine in a default configuration. The controller further receives signals indicative of data corresponding to at least one drilling hole and automatically positions the machine in an operating configuration.

A dummy tool is used to teach a robot the path the robot will follow to perform work on a workpiece to eliminate the possibility of damaging an actual tool during the training. The dummy tool provides the robot programmer an indication of potential collisions between the tool and the workpiece and other objects in the work cell when path is being taught. The dummy tool can have a detachable input/output device with a graphic user interface (GUI) that can communicate wirelessly with the robot controller. The dummy tool can also have a moveable camera attached thereto to track the relationship of the tool to objects in the work area.

Drilling apparatus and method, the apparatus comprising: a first robot (10); a first member (30) (e.g. a pressure foot) and a drilling tool (38) both coupled to the first robot (10); a second robot (12); and a second member (52) coupled to the second robot (12); wherein the apparatus is arranged to press the members (30, 52) against opposite sides of a part to be drilled (2, 100) (e.g. an aircraft panel) so as to hold the part (2, 100) and prevent deflection of at least a portion of the part (2, 100); and the first member (30) and the drilling tool (38) are arranged such that the drilling tool (38) may drill into the portion of the part (2, 100) of which deflection is opposed from the side of the part (2, 100) pressed against by the first member (30). The robots (10, 12) may be robotic arms.

Systems and methods for robotic positioning of multiple tools. The system may include one or more robotic devices, multiple tools, and one or more controllers. The one or more robotic devices are each configured to connect to the tools, move the tools to a desired work position, and release the tools at the work position. The tools are able to operate mechanically independently from the robotic devices to perform an operation at the position to which they are delivered. After releasing the tools, the robotic devices are able to perform other operations including moving additional tools to different work positions. The one or more controllers oversee the operation of the one or more robotic devices and tools and control the overall operation on a work piece.

An end effector provides one up assembly drilling through mated components, including a panel, by preloading the components to assure interface integrity, thus avoiding subsequent separation for cleaning and deburring. The end effector includes a drill and clamp dispenser for temporarily inserting and removing expansible single-sided clamps at various pre-drilled locations in the panel. In one method, pilot holes are first pre-drilled into mated components, for example an aircraft wing panel and a wing rib or spar; an initial pilot hole location is identified, and an expansible clamp is inserted into a pilot hole adjacent a desired initial fastener hole location. The clamp is torqued, causing its expansion for preloading the wing panel and rib and/or spar components under a predetermined load. The fastener hole is then drilled, the end effector untorques and removes the clamp and identifies a second (and/or next) pilot hole location, and the process is replicated.

A dummy tool is used to teach a robot the path the robot will follow to perform work on a workpiece to eliminate the possibility of damaging an actual tool during the training. The dummy tool provides the robot programmer an indication of potential collisions between the tool and the workpiece and other objects in the work cell when path is being taught. The dummy tool can have a detachable input/output device with a graphic user interface (GUI) that can communicate wirelessly with the robot controller. The dummy tool can also have a moveable camera attached thereto to track the relationship of the tool to objects in the work area.

Systems and methods are provided for identifying a location to perform work (e.g., drilling.). One exemplary method includes acquiring images of a hole in a first object from multiple lighting angles, processing the images to identify shadows cast by a wall of the hole at each of the lighting angles, and analyzing the shadows to determine an orientation of a central axis of the hole in a coordinate system of the first object. The method also includes, at a second object, selecting a location to drill that will be aligned with the central axis of the hole of the first object, and drilling the second object at the location.

A system and method for a self-contained self-calibrating modular manufacturing device having modular tools and parts configured to collectively accomplish a specific task or function. The modular device includes a housing that has a mount configured to engage a robotic arm or other form of maneuvering actuator (such a crane or gantry). The housing provides a base by which additional modules are mounted and coupled. The modular device also includes an interface configured to communicate with a remote control system capable of controlling the robotic arm. Such modules work in conjunction with each other to accomplish tasks and functions. In a self-contained self-calibrating modular manufacturing device, a processor disposed in the housing is configured to control the functional tools (e.g., each end-effector) independent of the overall manufacturing control system as well as use local sensors to determine aspects of an underlying manufactured items for calibration purposes.