US-12617101-B2 - Programmable robot

US12617101B2US 12617101 B2US12617101 B2US 12617101B2US-12617101-B2

Abstract

A programmable robot is configurable between a measuring configuration, in which a probe is operable, and a machining configuration, in which a tool is operable. The robot includes a carrier for carrying the probe and the tool, a position sensing arrangement for determining coordinate data, and a controller 7. The controller is configured to cause the carrier, in the measuring configuration, to move the probe to each of a plurality of reference features in a template held in a first orientation by a jig, wherein feedback via the probe enables the position sensing arrangement to determine coordinate data associated with the reference features. The controller is configured to, based on the determined data, cause the carrier, in the machining configuration, to return to each position corresponding to each reference feature location and machine a workpiece held in the first orientation.

Inventors

Robin Hardi
Harvey Brookes
John MUMFORD
Richard Cameron BLAIN

Assignees

AIRBUS OPERATIONS LIMITED
THE MANUFACTURING TECHNOLOGY CENTRE LIMITED

Dates

Publication Date: 20260505
Application Date: 20231026
Priority Date: 20221031

Claims (15)

1 . A programmable robot configurable between a measuring configuration, in which a probe is operable, and a machining configuration, in which a tool is operable, the robot comprising: a carrier for carrying the probe and the tool; a position sensing arrangement for determining coordinate data; and a controller configured to: cause the carrier, in the measuring configuration of the robot, to move the probe to each one of a plurality of reference features in a template held in a first orientation by a jig, such that feedback via the probe interacting with the template at each reference feature location enables the position sensing arrangement to determine a first set of coordinate data associated with the plurality of reference features; and on a basis of the determined first set of coordinate data, cause the carrier, in the machining configuration of the robot, to return to each position of the carrier corresponding to each reference feature location and machine, using the tool, a first workpiece held in the first orientation.
2 . The programmable robot according to claim 1 , wherein each reference feature of the plurality of reference features is a hole, such that the controller is configured to: cause the carrier, in the measuring configuration of the robot, to move the probe to each one of a plurality of reference holes in the template held in the first orientation by the jig, such that feedback via the probe interacting with the template at each reference feature location enables the position sensing arrangement to determine the first set of coordinate data associated with the plurality of reference features; and on the basis of the determined first set of coordinate data, cause the carrier, in the machining configuration of the robot, to return to each position of the carrier corresponding to each reference feature location and machine, using the tool, the first workpiece held in the first orientation.
3 . The programmable robot according to claim 1 , wherein the controller is configured to: cause the carrier, in the measuring configuration of the robot, to move the probe to each one of the plurality of reference features via a common datum, and cause the carrier, in the machining configuration of the robot, to return to each position of the carrier via the common datum.
4 . The programmable robot according to claim 1 , wherein the controller is configured to: determine the first set of coordinate data by determining a vector of each one of the plurality of reference features in the template, and cause the carrier to machine the first workpiece along a direction of the determined vector associated with each one of the plurality of reference features.
5 . The programmable robot according to claim 1 , wherein the controller is configured to: cause the carrier, in the measuring configuration of the robot, to move the probe to each one of the plurality of reference features by first moving to an indicated reference feature location according to predetermined coordinate data, that can be CAD data, and thereafter move the probe to an actual reference feature in the template held in the first orientation by the jig by searching for the actual reference feature through the feedback via the probe interacting with the template at each reference feature location.
6 . The programmable robot according to claim 1 , wherein the determined first set of coordinate data comprises coordinates of a center of each one of the plurality of reference features.
7 . The programmable robot according to claim 1 , comprising a memory to store the determined first set of coordinate data.
8 . The programmable robot according to claim 1 , wherein the controller is configured to: cause the carrier, in the measuring configuration of the robot, to move the probe to each one of the plurality of reference features in the template held in a second orientation by the jig, such that feedback via the probe interacting with a different side of the template at each reference feature location enables the position sensing arrangement to determine a second set of coordinates associated with the plurality of reference features; and on a basis of the determined second set of coordinate data, cause the carrier, in the machining configuration of the robot, to return to each position of the carrier corresponding to each reference feature location and machine, using the tool, a second workpiece held in the second orientation, such that the first workpiece and the second workpiece can be coupled together through respectively machined locations.
9 . A machining system comprising: a programmable robot according to claim 1 ; a template comprising a plurality of features; and a jig for holding the template.
10 . A method of machining using a programmable robot, the method comprising, under instruction from a controller: in a first mode of operation: moving a probe by a carrier to a plurality of reference features in a template held in a first orientation by a jig; and determining a first set of coordinate data associated with the plurality of reference features by a position sensing arrangement in response to feedback via the probe interacting with the template at each reference feature location; and in a second mode of operation: returning the carrier to each position of the carrier corresponding to each reference feature location using the determined first set of coordinate data, and machining, using a tool, a first workpiece held in the first orientation based on a returned position of the carrier.
11 . The method according to claim 10 , comprising removing the template from the jig after determining the first set of coordinate data, such that the template is absent from the jig when subsequently machining using the tool, the first workpiece held in the first orientation by the jig based on the returned position of the carrier.
12 . The method according to claim 10 , comprising repeating the first and second modes of operation using a different side of the template, held in a second orientation by the jig, and using a second workpiece, such that the first workpiece and the second workpiece can be coupled together by respectively machined locations.
13 . The method according to claim 10 , comprising, in the first mode of operation, resetting the carrier from each position of the carrier corresponding to each reference feature location to a common datum along a path, and returning the carrier to each position of the carrier corresponding to each reference feature location from the common datum along the path.
14 . A method of machining an aircraft structure, the method comprising: mounting an artefact in a jig to provide a datum; determining, using a programmable robot, coordinate data of a plurality of reference features in the artefact and orientation information of the robot associated with each one of the plurality of reference features; replacing the artefact mounted in the jig with an aircraft structure according to the datum; re-orientating the robot based on the orientation information of the robot associated with each one of the plurality of reference features; and machining, using a tool, the aircraft structure at each location corresponding to each one of the plurality of reference features in the artefact.
15 . A non-transitory computer-readable storage medium, the computer-readable storage medium including program code comprising programming instructions that when executed by a processing circuit cause the processing circuit to: in a first mode of operation: move a probe by a carrier to a plurality of reference features in a template held in a first orientation by a jig; and determine a first set of coordinate data associated with the plurality of reference features by a position sensing arrangement in response to feedback via the probe interacting with the template at each reference feature location; and in a second mode of operation: return the carrier to each position of the carrier corresponding to each reference feature location using the determined first set of coordinate data, and machine, using a tool, a first workpiece held in the first orientation based on a returned position of the carrier.

Description

TECHNICAL FIELD The disclosure herein relates to a programmable robot. More particularly, but not exclusively, the disclosure herein concerns a programmable robot to determine a first set of coordinate data associated with a plurality of reference features in a template held by a jig, and, on the basis of the determined data, to return to each position corresponding to each reference feature location and machine a first workpiece held by the jig. The disclosure herein also concerns a machining system comprising the programmable robot, an aircraft comprising an aircraft structure machined by the programmable robot, a method of machining using a programmable robot, and a computer program comprising instructions, which, when the program is executed by a computer, cause the computer to carry out the method. BACKGROUND Workpieces can be assembled together by individually machining a matching pattern of features (such as a hole pattern) in each workpiece and coupling the workpieces using fasteners (for example, bolts) through matching features (such as holes). In some applications, such as the manufacture of components in the aerospace industry, a high degree of precision is required in matching relative locations of the features in the respective workpiece. Some manual processes with high accuracy can be inefficient from a manufacturing standpoint and can hold up the assembly line. Typically, a template, unintended for assembly, can be used to transfer a hole pattern to a workpiece that is intended for assembly into the final product, for example, an aircraft. The template, comprising the hole pattern, is overlaid on the workpiece and fixed in position relative to the workpiece once accurately aligned. Each hole in the hole pattern of the template is used as a guide for the direction and location of the hole to be drilled. Each hole is drilled into the workpiece located below the template using a drill. The drill is manually moved to each other hole location while the template remains firmly fixed in place. In some instances, it can be impractical and/or time consuming to overlay the template and ensure the template is held relative to the workpiece throughout the drilling process. Alternatively, a machine can be programmed using data about the hole pattern to be formed in the workpiece from design drawing data, such as a CAD file. The hole pattern is then transferred to the workpiece directly using the design drawing data. Although the physical template is not used, inaccuracies inherent to the machine may go undetected, which could result in a mismatch of respective hole locations and/or entire hole patterns. SUMMARY The disclosure herein seeks to mitigate the above-mentioned problems. Alternatively or additionally, the disclosure herein seeks to provide an improved programmable robot, machining system comprising a programmable robot, method of machining using a programmable robot, and/or method of machining an aircraft structure. The disclosure herein provides, according to a first aspect, a programmable robot. The robot is configurable between a measuring configuration, in which a probe is operable, and a machining configuration, in which a tool is operable. The robot may comprise a carrier for carrying the probe and the tool. The robot may comprise a position sensing arrangement for determining coordinate data and optionally, position information about the carrier. The robot may comprise a controller. The controller may be configured to cause the carrier, in the measuring configuration of the robot, to move the probe to each one of a plurality of reference features in a template. The template may be held in a first orientation by a jig (for example, according to a first datum). Feedback via the probe interacting with the template at each reference feature location may enable the position sensing arrangement to determine a first set of coordinate data associated with the plurality of reference features, and optionally, a first set of positions of the carrier associated with the plurality of reference features. On the basis of the determined first set of coordinate data and/or the determined first set of positions of the carrier, the controller may cause the carrier, in the machining configuration of the robot, to return to each position of the carrier corresponding to each reference feature location and optionally machine, using the tool, a first workpiece held in the first orientation optionally by the jig or another jig (for example, according to the first datum determined by the first orientation of the template). Programmable robots, in accordance with the disclosure herein, may learn information about a predetermined pattern of features (for example, a hole pattern) and use the learnt information to directly transfer at least one aspect of the pattern of features to a workpiece. Such robots may be regarded as a machine that programmes itself under instructions from the controller. Such robots may increa