Systems and methods for assembling structural components are disclosed. The systems and methods consider a sequence, operations of the sequence, and an approach vector in placing structural members (including structural members with pre-attached fasteners) for assembling structural components.

A method for automated part probing using a physical machine defining a physical working volume, the method including: generating a virtual model based on a virtual part design received from a user account, the virtual model comprising a virtual part model, based on the virtual part design, virtually fixed to a virtual fixture plate arranged within a virtual working volume representative of the physical working volume; generating a probing routine based on the virtual model; sending the probing routine to the machine; receiving probe outputs from the machine; and validating the virtual model based on the probe outputs.

Automated fixture layout is approached in two distinct stages. First, the spatial locations of clamping points on the work piece are determined to ensure immobility of the fixtured part under any infinitesimal perturbation. Second, spatial locations are matched against a user-specified library of reconfigurable clamps to synthesize a valid fixture layout or configuration that includes clamps that are accessible and collision free. The spatial locations matching during the second stage can be the same spatial locations chosen in the first stage to ensure immobility, or a different set of spatial locations.

An assembly engine is configured to generate, based on a computer-aided design (CAD) assembly, a set of motion commands that causes the robot to manufacture a physical assembly corresponding to the CAD assembly. The assembly engine analyzes the CAD assembly to determine an assembly sequence for various physical components to be included in the physical assembly. The assembly sequence indicates the order in which each physical component should be incorporated into the physical assembly and how those physical components should be physically coupled together. The assembly engine further analyzes the CAD assembly to determine different component paths that each physical component should follow when being incorporated into the physical assembly. Based on the assembly sequence and the component paths, the assembly engine generates a set of motion commands that the robot executes to assemble the physical components into the physical assembly.

A method for automated part probing using a physical machine defining a physical working volume, the method including: generating a virtual model based on a virtual part design received from a user account, the virtual model comprising a virtual part model, based on the virtual part design, virtually fixed to a virtual fixture plate arranged within a virtual working volume representative of the physical working volume; generating a probing routine based on the virtual model; sending the probing routine to the machine; receiving probe outputs from the machine; and validating the virtual model based on the probe outputs.

Automated fixture layout is approached in two distinct stages. First, the spatial locations of clamping points on the work piece are determined to ensure immobility of the fixtured part under any infinitesimal perturbation. Second, spatial locations are matched against a user-specified library of reconfigurable clamps to synthesize a valid fixture layout or configuration that includes clamps that are accessible and collision free. The spatial locations matching during the second stage can be the same spatial locations chosen in the first stage to ensure immobility, or a different set of spatial locations.

A method for automated part probing using a physical machine defining a physical working volume, the method including: generating a virtual model based on a virtual part design received from a user account, the virtual model comprising a virtual part model, based on the virtual part design, virtually fixed to a virtual fixture plate arranged within a virtual working volume representative of the physical working volume; generating a probing routine based on the virtual model; sending the probing routine to the machine; receiving probe outputs from the machine; and validating the virtual model based on the probe outputs.

Disclosed is a method of producing a machining fixture for fixedly holding a workpiece during machining of that workpiece. The method comprises: providing an initial machining fixture comprising a plurality of receiving elements for receiving the workpiece to be machined; determining a datum, the datum being dependent upon the relative positions of the receiving elements; determining positions and orientations of one or more reference surfaces with respect to the datum; measuring the surface of the initial machining fixture with respect to the datum; and, thereafter, controlling machining apparatus with respect to the datum to machine the initial machining fixture to form the one or more reference surfaces, thereby producing the machining fixture.

Disclosed is a method of producing a machining fixture for fixedly holding a workpiece during machining of that workpiece. The method comprises: providing an initial machining fixture comprising a plurality of receiving elements for receiving the workpiece to be machined; determining a datum, the datum being dependent upon the relative positions of the receiving elements; determining positions and orientations of one or more reference surfaces with respect to the datum; measuring the surface of the initial machining fixture with respect to the datum; and, thereafter, controlling machining apparatus with respect to the datum to machine the initial machining fixture to form the one or more reference surfaces, thereby producing the machining fixture.