Abstract: Systems and related methods are provided for adjusting the position and orientation of an end effector of a multi-axis machine (e.g., a manipulable cutting head of a fluid jet cutting machine) relative to a base reference frame. Systems include an adjustable tool mount having a base structure that includes portions or regions that are selectively deformable to adjust a position and an orientation of a tool supported by the adjustable tool mount.

Abstract: High-pressure fluid jet systems are provided which include a pump to selectively provide a source of high-pressure fluid, a cutting head assembly configured to receive the high-pressure fluid and generate a high-pressure fluid jet for processing workpieces or work surfaces, and a fluid distribution system in fluid communication with the pump and the cutting head assembly to route the high-pressure fluid from the pump to the cutting head assembly. The pump, the cutting head assembly and/or the fluid distribution system include at least one fluid distribution component having a unitary body formed from an additive manufacturing or casting process with an internal passage having at least a curvilinear portion to efficiently route matter through the fluid jet system. Example fluid distribution components include fittings, valve bodies, cutting head bodies and nozzles of the high-pressure fluid jet systems.

Abstract: A coupler assembly is provided for coupling components in a power transmission system, such as a rack and pinion drive system. The coupler assembly includes a floating mount and a pair of clamp members movable between an unfastened configuration in which the floating mount is adjustably supported between the clamp members and a fastened configuration in which the floating mount is fixedly secured between the clamp members. At least a pitch and a yaw of the floating mount are adjustable when the clamp members are in the unfastened configuration. Methods and systems which relate to or include the aforementioned coupler assembly are also provided.

Abstract: Systems and related methods are provided for maintaining a spatial relationship between a tool of the multi-axis machine (e.g., fluid jet nozzle of a fluid jet cutting machine) and a workpiece to be processed by the tool. An example system includes a contour follower apparatus having a sensor and a gimbal assembly operable with the sensor to sense a deviation between a machine focal point and a gimbal assembly focal point defined by the gimbal assembly as the gimbal assembly rides upon the surface of the workpiece during operation. The system may further include a gimbal mount assembly configured to sense a collision event of the gimbal assembly with another object.

Abstract: Methods, systems, and techniques for automatically determining jet orientation parameters to correct for potential deviations in three dimensional part cutting are provided. Example embodiments provide an Adaptive Vector Control System (AVCS), which automatically determines speeds and orientation parameters of a cutting jet to attempt to insure that a part will be cut within prescribed tolerances where possible. In one embodiment, the AVCS determines the tilt and swivel of a cutting head by mathematical predictive models that examine the cutting front for each of “m” hypothetical layers in a desired part, to better predict whether the part will be within tolerances, and to determine what corrective angles are needed to correct for deviations due to drag, radial deflection, and/or taper.

Abstract: Fluid jet systems, components and related methods are provided which are well adapted for processing workpieces under particularly work-friendly conditions. Embodiments include fluid jet systems and related methods that reduce, minimize or eliminate a gap between a workpiece being processed and jet receiving devices that receive and dissipate the energy of a fluid jet passing through the workpiece. Other embodiments include fluid jet systems and related methods involving fluid jet processing of workpieces in a submerged condition. Still further embodiments include fluid jet systems and related methods involving position and orientation adjustment of a fluid jet receptacle to coordinate the path of an incoming fluid jet with a central axis or other feature of the fluid jet receptacle.

Abstract: Fluid jet systems, components and related methods are provided which are well adapted for processing workpieces under particularly work-friendly conditions. Embodiments include fluid jet systems and related methods that reduce, minimize or eliminate a gap between a workpiece being processed and jet receiving devices that receive and dissipate the energy of a fluid jet passing through the workpiece. Other embodiments include fluid jet systems and related methods involving fluid jet processing of workpieces in a submerged condition. Still further embodiments include fluid jet systems and related methods involving position and orientation adjustment of a fluid jet receptacle to coordinate the path of an incoming fluid jet with a central axis or other feature of the fluid jet receptacle.

Abstract: High-pressure fluid jet systems are provided which include a pump to selectively provide a source of high-pressure fluid, a cutting head assembly configured to receive the high-pressure fluid and generate a high-pressure fluid jet for processing workpieces or work surfaces, and a fluid distribution system in fluid communication with the pump and the cutting head assembly to route the high-pressure fluid from the pump to the cutting head assembly. The pump, the cutting head assembly and/or the fluid distribution system include at least one fluid distribution component having a unitary body formed from an additive manufacturing or casting process with an internal passage having at least a curvilinear portion to efficiently route matter through the fluid jet system. Example fluid distribution components include fittings, valve bodies, cutting head bodies and nozzles of the high-pressure fluid jet systems.

Abstract: A cutting head of a waterjet cutting system is provided having an environment control device and a measurement device. The environment control device is positioned to act on a surface of a workpiece at least during a measurement operation to establish a measurement area on the surface of the workpiece substantially unobstructed by fluid. The measurement device is positioned to selectively obtain information from within the measurement area indicative of a position of the cutting head relative to the workpiece. A control system is further provided and operable to position the cutting head relative to the workpiece at a standoff distance based at least in part on the information indicative of the position of the cutting head relative to the workpiece obtained by the measurement device. A method of operating a waterjet cutting system is also provided.

Abstract: A jet receiving receptacle is provided which is coupleable to a high pressure fluid jet system opposite a nozzle thereof to receive a fluid jet discharged from the nozzle after it acts on a workpiece. The jet receiving receptacle may include an inlet feed component having a tapered inlet that defines a jet receiving surface about a central axis to receive the fluid jet and direct the fluid jet downstream and toward the central axis. The jet receiving receptacle may further include a drive mechanism adapted to rotate the inlet feed component about the central axis such that impact of the fluid jet with the inlet feed component is distributed around the jet receiving surface. The drive mechanism may rotate the inlet feed component continuously or intermittently. Fluid jet cutting systems incorporating a jet receiving receptacle and related methods are also provided.

Abstract: A processing apparatus is provided to process a workpiece. The processing apparatus can have a low-profile nozzle system capable of navigating through spaces in order to process target regions with relatively small clearances. A fluid jet outputted from the nozzle system is used to cut, mill, or otherwise process the target region of the workpiece.

Abstract: High-pressure fluid jet systems are provided which include a pump to selectively provide a source of high-pressure fluid, a cutting head assembly configured to receive the high-pressure fluid and generate a high-pressure fluid jet for processing workpieces or work surfaces, and a fluid distribution system in fluid communication with the pump and the cutting head assembly to route the high-pressure fluid from the pump to the cutting head assembly. The pump, the cutting head assembly and/or the fluid distribution system include at least one fluid distribution component having a unitary body formed from an additive manufacturing or casting process with an internal passage having at least a curvilinear portion to efficiently route matter through the fluid jet system. Example fluid distribution components include fittings, valve bodies, cutting head bodies and nozzles of the high-pressure fluid jet systems.

Abstract: A waterjet system for generating and delivering fluid jets suitable for processing a workpiece has a cutting head body and a mixing tube. The cutting head body includes a mixing chamber and a bore. The bore is positioned downstream of the mixing chamber, and an abrasive fluid jet from the mixing chamber passes through the mixing tube. The mixing tube has a first coupler adapted to magnetically couple the mixing tube to the cutting head body when the mixing tube is installed. The cutting head body has a second coupler positioned to engage the first coupler of the mixing tube to keep the mixing tube properly positioned during operation of the waterjet system.

Abstract: A jet receiving receptacle is provided which is coupleable to a high-pressure fluid jet system opposite a nozzle thereof to receive a fluid jet discharged from the nozzle after it acts on a workpiece. The jet receiving receptacle may include an elongated inlet alignable with a direction of travel of the nozzle to receive the fluid jet in a deflected state. The jet receiving receptacle may further include a jet deflection device positioned downstream of the elongated inlet to redirect at least a portion of the fluid jet and a jet rebound device located upstream of the jet deflection device to be impinged on by the redirected portion of the fluid jet. The jet deflection device and jet rebound device may form, in combination with a housing, a device to trap the fluid jet. Fluid jet cutting systems incorporating a jet receiving receptacle and related methods are also provided.

Abstract: Methods, systems, and techniques for automatically determining jet orientation parameters to correct for potential deviations in three dimensional part cutting are provided. Example embodiments provide an Adaptive Vector Control System (AVCS), which automatically determines speeds and orientation parameters of a cutting jet to attempt to insure that a part will be cut within prescribed tolerances where possible. In one embodiment, the AVCS determines the tilt and swivel of a cutting head by mathematical predictive models that examine the cutting front for each of “m” hypothetical layers in a desired part, to better predict whether the part will be within tolerances, and to determine what corrective angles are needed to correct for deviations due to drag, radial deflection, and/or taper.

Abstract: A processing apparatus is provided to process a workpiece. The processing apparatus can have a low-profile nozzle system capable of navigating through spaces in order to process target regions with relatively small clearances. A fluid jet outputted from the nozzle system is used to cut, mill, or otherwise process the target region of the workpiece.

Abstract: A manufacturing system includes a configurable positioning apparatus and machining system for processing a workpiece retained by the positioning apparatus. The positioning apparatus has different configurations for retaining different types of workpieces, such as panels, fuselages, airfoil skins, and engine housings. The positioning apparatus includes a first support rail and a second support rail spaced apart from the first support rail. The first and second support rails support a plurality of stackable headers that cooperate to position the workpiece. The headers have adjustable heights along their lengths in order to accommodate the shape of the workpiece.