Abstract: Techniques of performing a manufacturing operation on a workpiece are disclosed. In one embodiment, a method includes forming an indexing hole in the workpiece. A coordinating pin may be installed into the indexing hole, the coordinating pin including a quantum of indexing information. A sensor may be positioned proximate the coordinating pin. The quantum of indexing information may be sensed with a sensor. A manufacturing operation may be performed on the workpiece based at least partially on the quantum of indexing information.

Abstract: Apparatus and methods for manufacturing operations are disclosed. In one embodiment, a vacuum cup assembly includes a housing having a vacuum generator formed therein, and a compliant sealing member coupled to the housing. The vacuum generator is coupleable to a source of pressurized fluid and is adapted to generate a reduced pressure region. The sealing member forms an enclosable region in fluid communication with the reduced pressure region. In another embodiment, a method of performing a manufacturing operation includes installing a coordinating pin into an indexing hole, the coordinating pin including a quantum of indexing information. The quantum of indexing information is sensed, and a manufacturing operation is performed based at least partially on the quantum of indexing information.

Abstract: A motor assembly including a body that includes a plurality of cylinders and a plurality of air channels and a conical shaped piston slidably coupled within each of said plurality of cylinders. The motor assembly also includes a rotatable timing shaft positioned concentric to and at least partially housed within the body and in flow communication with an air source and the plurality of air channels and a cam plate coupled to the timing shaft and configured to engage the pistons and generate torque.

Abstract: A conformal vacuum cup provides a machine tool attachment fitting usable in a flexible-track drill system. Using multiple, independently articulated stiffeners, the conformal vacuum cup conforms to the contour of complex aerostructure surface shapes. The individual stiffeners are decoupled from each other to some extent by grooves and slots molded into resilient overmolding material to support long-axis curving. Spacing pins employ a domed shape consonant with the elastic deformation of the workpiece surface under load. The pins employ a hard material to prevent particle embedment in use and to control position tolerance for drill heads and other tools traveling on the flexible track. Partial holes in each vacuum cup are blocked by diaphragms. Interconnection from a vacuum system manifold to the vacuum cups can be realized by penetrating the diaphragms and inserting barbed fittings connected by vacuum tubing.

Abstract: An automatic position-locking tool carrier apparatus and method include a carriage that rides on a first rail and a second rail translatably connected to the carriage perpendicular to the first rail. Pinion gears that engage with the two rails are attached to the carriage and coupled to position encoders which transmit position signals to a controller. The controller produces control signals to control brake mechanisms coupled to the pinion gears. Translational motion of the carriage and the second rail are limited or prevented when the position of the carriage and the second rail are within predetermined limitations from a predetermined location, fixing the position of an end-effector head attached at one end of the second rail. The carriage and the second rail are propelled by forces external to the system.

Abstract: A conformal vacuum cup provides a machine tool attachment fitting usable in a flexible-track drill system. Using multiple, independently articulated stiffeners, the conformal vacuum cup conforms to the contour of complex aerostructure surface shapes. The individual stiffeners are decoupled from each other to some extent by grooves and slots molded into resilient overmolding material to support long-axis curving. Spacing pins employ a domed shape consonant with the elastic deformation of the workpiece surface under load. The pins employ a hard material to prevent particle embedment in use and to control position tolerance for drill heads and other tools traveling on the flexible track. Partial holes in each vacuum cup are blocked by diaphragms. Interconnection from a vacuum system manifold to the vacuum cups can be realized by penetrating the diaphragms and inserting barbed fittings connected by vacuum tubing.

Abstract: A rail system for positioning a toolhead above a workpiece uses a rack cut into one edge of the rail and driven by a pinion gear whose shaft is approximately perpendicular to a workpiece to couple the rail to the toolhead. Multiple rollers placed on the toolhead allow contact between the toolhead and the rail to be effectively continuous despite the cutting away of as much as or more than two-thirds of the rail edge to provide rack teeth. Separating thickness axis containment from transverse with a square rail edge and separate thickness axis and transverse rollers allows the toolhead to follow a rail as the rail flexes over a curved surface with minimal position error. Several variations in rail, bearing, and rack implementation can realize comparable results.

Abstract: A flexible rail machine tool couples temporarily to a structure by vacuum cups and positions a tool head at any desired point over an area. The toolhead can perform operations such as drilling, bolt insertion, and acquisition of dimension data. The flexible rail can conform to surface curvature in one or more axes. Tool head perpendicularity to the structure can be sensed and adjusted as needed. The as-attached position of the rail may be compensated for through coordinate transformation, allowing holes, for example, to be placed with substantial precision.

Abstract: Apparatus and methods for manufacturing operations using non-contact position sensing are disclosed. In one embodiment, an apparatus includes a track assembly adapted to be attached to a workpiece, a carriage assembly moveably coupled to the track assembly and moveable relative to the workpiece, and a position sensor. The position sensor includes a sensor element adapted to detect at least one edge of an index feature on the workpiece from a distance away from the index feature. In an alternate embodiment, the position sensor may include a sensing circuit that receives an analog signal from the sensing element and provides both analog and digital output signals. In another embodiment, a controller that controls manufacturing operations may be mounted directly on the carriage assembly.

Abstract: Apparatus and methods for manufacturing operations are disclosed. In one embodiment, a vacuum cup assembly includes a housing having a vacuum generator formed therein, and a compliant sealing member coupled to the housing. The vacuum generator is coupleable to a source of pressurized fluid and is adapted to generate a reduced pressure region. The sealing member forms an enclosable region in fluid communication with the reduced pressure region. In another embodiment, a method of performing a manufacturing operation includes installing a coordinating pin into an indexing hole, the coordinating pin including a quantum of indexing information. The quantum of indexing information is sensed, and a manufacturing operation is performed based at least partially on the quantum of indexing information.