Abstract: A rotary-drive sub-assembly includes a tool and a tool retainer. The tool includes a fastener-engagement portion, a first threaded portion, and a tool-change-engagement portion between the fastener-engagement portion and the first threaded portion. The tool retainer includes a body and a retaining member. The body includes a symmetry axis, a second threaded portion, configured to be threadably fastened with the first threaded portion of the tool so that the tool is rotationally anchored relative to the body of the tool retainer about the symmetry axis and is translationally anchored relative to the body of the tool retainer along the symmetry axis, and a key, fixed relative to the second threaded portion. The tool retainer further includes a retaining member that is removably coupled to the body at a fixed location.

Abstract: A rotary-drive sub-assembly includes a tool and a tool retainer. The tool includes a fastener-engagement portion, a first threaded portion, and a tool-change-engagement portion between the fastener-engagement portion and the first threaded portion. The tool retainer includes a body and a retaining member. The body includes a symmetry axis, a second threaded portion, configured to be threadably fastened with the first threaded portion of the tool so that the tool is rotationally anchored relative to the body of the tool retainer about the symmetry axis and is translationally anchored relative to the body of the tool retainer along the symmetry axis, and a key, fixed relative to the second threaded portion. The tool retainer further includes a retaining member that is removably coupled to the body at a fixed location.

Abstract: A rotary-drive sub-assembly includes a tool and a tool retainer. The tool includes a first body and a second body. The first body includes a tool-change-engagement portion and a first threaded portion that is fixed relative to the tool-change-engagement portion. The second body includes a fastener-engagement portion. The second body is translatable relative to the first body, co-axially with the first body, and is co-axially rotationally fixed relative to the first body. The tool further includes a keeper, fixed within the first body, and a resilient member, captured between the second body and the keeper. The tool also includes a tool retainer, including a second threaded portion, configured to be threadably fastened with the first threaded portion of the first body, and a key, fixed relative to the second threaded portion.

Abstract: A tool-change station includes a base, and a first tool-change member that is rotatably coupled to the base. The first tool-change member includes a first tool-engagement portion, geometrically complementary with a tool-change-engagement portion of a tool of a rotary drive.

Abstract: A robotic end effector quick change coupling apparatus employs a drive motor assembly having a center drive interface. A coupling component having a magnetic element extends from the drive motor assembly concentric with the center drive interface. An end effector tool has a drive connection adapted to removably receive the center drive interface. A mating coupling component having a mating magnetic element extends from the end effector tool concentric with the drive connection. The magnetic element and mating magnetic element are separably engaged by mutual magnetic attraction to couple the end effector to the drive motor assembly.

Abstract: A robotic end effector quick change coupling apparatus employs a drive motor assembly having a center drive interface. A coupling component having a magnetic element extends from the drive motor assembly concentric with the center drive interface. An end effector tool has a drive connection adapted to removably receive the center drive interface. A mating coupling component having a mating magnetic element extends from the end effector tool concentric with the drive connection. The magnetic element and mating magnetic element are separably engaged by mutual magnetic attraction to couple the end effector to the drive motor assembly.

Abstract: A computer implemented method may include the steps of: (1) providing a first point cloud representative of at least a bare portion of a surface of an object relative to a reference portion of the surface, (2) providing a second point cloud representative of at least a coated portion of the surface relative to the reference portion, (3) registering the first point cloud and the second point cloud with respect to a common reference coordinate system, (4) registering a first reference portion subset of the first data points representative of the reference portion and a second reference portion subset of the second data points representative of the reference portion, and (5) calculating difference values indicative of a thickness of the surface coating based on differences between a coated portion subset of the second data points and a bare portion subset of the first data points.

Abstract: A coating application system may include a pair of towers movable along a respective pair of floor tracks. A crossbeam may extend between the pair of towers. The cross beam may have opposing beam ends. A universal joint may couple each beam end to a tower to allow the crossbeam to rotate about a vertical axis and about a horizontal axis. A robotic device may be mounted to the crossbeam. The robotic device may include an end effector for performing one or more operations on an aircraft exterior surface.

Abstract: A system for printing an image on a surface includes a robot, a printhead having a reference line printing mechanism, and a reference line sensor. The robot has at least one arm. The printhead is mounted to the arm and is movable by the arm over a surface along a rastering path while printing a new image slice on the surface. The reference line printing mechanism is configured to print a reference line on the surface when printing the new image slice. The reference line sensor is configured to sense the reference line of an existing image slice and transmit a signal to the robot causing the arm to adjust the printhead in a manner such that a side edge of the new image slice is aligned with the side edge of the existing image slice.

Abstract: A system for printing an image on a surface may include a robot having at least one arm. A printhead may be mounted to the arm and may be movable by the arm over a surface along a rastering path while printing an image slice on the surface. The image slice may have opposing side edges. The printhead may be configured to print the image slice with an image gradient band along at least one of opposing side edges wherein an image intensity within the image gradient band decreases from an inner portion of the image gradient band toward the side edge.

Abstract: A coating application system may include a pair of towers movable along a respective pair of floor tracks. A crossbeam may extend between the pair of towers. The cross beam may have opposing beam ends. A universal joint may couple each beam end to a tower to allow the crossbeam to rotate about a vertical axis and about a horizontal axis. A robotic device may be mounted to the crossbeam. The robotic device may include an end effector for performing one or more operations on an aircraft exterior surface.

Abstract: The different advantageous embodiments may provide an apparatus comprising a vision system, a drilling tool, and a system controller. The vision system may be configured to generate data about a number of laser signatures on a surface of a workpiece. The drilling tool may be configured to drill a number of holes in the surface of the workpiece. The system controller may be configured to generate drilling instructions for the drilling tool using the data generated by the vision system.

Abstract: The different advantageous embodiments may provide an apparatus comprising a vision system, a drilling tool, and a system controller. The vision system may be configured to generate data about a number of laser signatures on a surface of a workpiece. The drilling tool may be configured to drill a number of holes in the surface of the workpiece. The system controller may be configured to generate drilling instructions for the drilling tool using the data generated by the vision system.

Abstract: A servo drill spindle includes a spindle body, an air motor slidably carried by the spindle body, a spindle extension drivingly engaged by the air motor, a cutting tool drivingly engaged by the spindle extension and a servo motor engaging the air motor and operable to advance the air motor along the spindle body.

Abstract: A method and apparatus for controlling an air motor. Speed information is received for an operation using an apparatus comprising the air motor having an inlet and an exhaust, and a valve comprising a body with a first port, a second port, and a third port. The first port is connected to the air motor, the second port is configured for connection to an air supply, and the third port is configured to vent air out of the body. A first flow of air is controlled in the body between the first port and the second port and a second flow of air is controlled out of the body through the third port to control a speed of the operation.

Abstract: Methods and systems for concentric clamping for manufacturing assemblies are disclosed. In one embodiment, a drilling assembly includes a spindle assembly configured to perform a drilling operation at a drilling location on a workpiece, and a clamping assembly having an actuator concentrically disposed about the spindle assembly. A nosepiece is coupled to the actuator and is configured to apply a clamping force concentrically about the drilling location on the workpiece. The actuator may include an inner housing having an outwardly extending flange, and an outer housing disposed about the flange of the inner housing. Pressurization of a first chamber moves the inner housing forwardly and applies the clamping force of the nosepiece against the workpiece, and pressurization of a second chamber moves the inner housing aftwardly and retracts the nosepiece away from the workpiece.

Abstract: A collet clamping nosepiece for a power feed drill is described which includes at least one clamping piston located along a centerline of the nosepiece, an expansion mandrel comprising a frusto-conical exterior surface, and an expandable collet. The expandable collet is configured to substantially surround the expansion mandrel and operatively connect to the at least one clamping piston. Operation of the at least one clamping piston causes the mandrel to move along the exterior surface of the expansion mandrel for engagement and disengagement of the collet with a bore configured for insertion of the collet.

Abstract: Spindle assemblies with inline direct drive feed are disclosed. In one embodiment, a manufacturing system includes a support structure configured to be positioned proximate a workpiece, a carriage moveably coupled to the support structure, and a head assembly coupled to the carriage. The head assembly includes a spindle assembly, comprising a feed unit and a spindle unit. The feed unit includes a feed motor coupled to a drive mechanism, the feed motor and the drive mechanism being disposed along a longitudinal axis of the spindle assembly. The spindle unit has an aft end operatively coupled to the drive mechanism of the feed unit, the spindle unit including a fluid-driven motor coupled to a tool collet chuck, the spindle unit being configured to translate along the longitudinal axis by actuation of the feed motor.

Abstract: A self-normalizing contour surface drilling apparatus drills holes into contour surfaces with the drill bit of the apparatus oriented normally to the contour surface. The apparatus first determines a location of a hole to be drilled and the orientation of the drill bit relative to the surface at the hole location, and adjusts the position of the drill bit so that the drill bit is positioned normally to the hole location. The apparatus then drills the hole at the location, and then repeats the process seeking out the next location for a drilled hole.

Abstract: A servo drill spindle includes a spindle body, an air motor slidably carried by the spindle body, a spindle extension drivingly engaged by the air motor, a cutting tool drivingly engaged by the spindle extension and a servo motor engaging the air motor and operable to advance the air motor along the spindle body.