Abstract: A drilling end effector is provided for drilling a workpiece having a workpiece surface. The drilling end effector includes a chuck configured to hold a drilling tool, and a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion, at least one suction cup, and at least one suction feed line. The at least one suction cup is fluidly connected to the at least one suction feed line that is configured to be fluidly connected to a suction system. The at least one suction cup is configured to be engaged in physical contact with the workpiece surface and pulled under suction by the suction system such that the at least one suction cup adheres to the workpiece surface to thereby hold the end portion of the nosepiece on the workpiece surface.

Abstract: An aircraft surface cover is provided. The aircraft surface cover includes a cover member that is configured to be removably secured to an aircraft structure. The cover member includes an exterior surface that has a microtextured surface including microtexture ribs that are configured to improve aerodynamic performance of the aircraft structure.

Abstract: A drilling system is provided for drilling a workpiece. The drilling system includes a pattern generator configured to apply a pattern on a workpiece surface of the workpiece at a reference location relative to a target drilling location. The drilling system includes a drilling end effector, which includes a chuck configured to hold a drilling tool. The drilling end effector also includes a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion that is configured to be held on the workpiece surface of the workpiece. The drilling end effector also includes a camera configured to acquire an image of an area of the workpiece surface that includes the pattern. The image acquired by the camera indicates whether the end portion of the nosepiece is aligned with the pattern on the workpiece surface.

Abstract: A positioning device for positioning a drilling tool of a drilling apparatus relative to a workpiece includes a cage mounted to the drilling apparatus such that the cage at least partially surrounds the drilling tool. The cage includes an end portion that includes an alignment surface that is configured to be engaged in physical contact with a workpiece surface of the workpiece. The alignment surface of the cage is oriented relative to a centerline axis of the drilling tool such that the centerline axis extends approximately normal to the workpiece surface when the alignment surface of the cage is in contact with the workpiece surface. The positioning device also includes a laser projector mounted to the cage such that the laser projector is configured to project an illuminated dot onto the workpiece surface that indicates where the centerline axis of the drilling tool intersects the workpiece surface.

Abstract: A drilling end effector is provided for drilling a workpiece having a workpiece surface. The drilling end effector includes a chuck configured to hold a drilling tool, and a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion. The nosepiece includes at least one suction cup and at least one suction feed line. The at least one suction cup is fluidly connected to the at least one suction feed line. The at least one suction feed line is configured to be fluidly connected to a suction system. The at least one suction cup is configured to be engaged in physical contact with the workpiece surface and pulled under suction by the suction system such that the at least one suction cup adheres to the workpiece surface to thereby hold the end portion of the nosepiece on the workpiece surface.

Abstract: A drilling system is provided for drilling a workpiece. The drilling system includes a pattern generator configured to apply a pattern on a workpiece surface of the workpiece at a reference location relative to a target drilling location. The drilling system includes a drilling end effector, which includes a chuck configured to hold a drilling tool. The drilling end effector also includes a nosepiece configured to at least partially surround the drilling tool when the drilling tool is held by the chuck. The nosepiece includes an end portion that is configured to be held on the workpiece surface of the workpiece. The drilling end effector also includes a camera configured to acquire an image of an area of the workpiece surface that includes the pattern. The image acquired by the camera indicates whether the end portion of the nosepiece is aligned with the pattern on the workpiece surface.

Abstract: A positioning device for positioning a drilling tool of a drilling apparatus relative to a workpiece includes a cage mounted to the drilling apparatus such that the cage at least partially surrounds the drilling tool. The cage includes an end portion that includes an alignment surface that is configured to be engaged in physical contact with a workpiece surface of the workpiece. The alignment surface of the cage is oriented relative to a centerline axis of the drilling tool such that the centerline axis extends approximately normal to the workpiece surface when the alignment surface of the cage is in contact with the workpiece surface. The positioning device also includes a laser projector mounted to the cage such that the laser projector is configured to project an illuminated dot onto the workpiece surface that indicates where the centerline axis of the drilling tool intersects the workpiece surface.

Abstract: A method for implementing machining tasks for an object. The method identifies location coordinates for a plurality of holes. A task file contains the machining tasks. The robotic devices use the task files to perform the machining tasks. A minimum number of positioning stations is determined where a portion of the machining tasks will be performed by the robotic devices. An ordered sequence for performing the machining tasks is calculated and path a path with the near-minimum distance is determined. Robotic control files are created that cause the robotic devices to perform the machining tasks. The robotic control files are output to the robotic devices to perform the machining tasks to form the plurality of holes.

Abstract: An aircraft surface cover is provided. The aircraft surface cover includes a cover member that is configured to be removably secured to an aircraft structure. The cover member includes an exterior surface that has a microtextured surface including microtexture ribs that are configured to improve aerodynamic performance of the aircraft structure.

Abstract: A method and system for drilling holes in a repaired composite structure. Four corner holes are selected from holes outside of a repaired area in the repaired composite structure. The four corner holes define a rectangle encompassing the repaired area with sides that each include a pair of corner holes with intermediate holes in between. A surface representation is generated based on a scan of the repaired composite structure that includes the rectangle. Side hole locations between a corresponding pair of corner holes are generated for each side of the rectangle. Grid vector lines are generated between corresponding pairs of side hole locations on opposite sides of the rectangle. The grid vector lines intersect each other at intersection points on the surface representation. Point coordinates are determined for intersection points that lie within the repaired area. A path is created for drilling holes at point coordinates for the intersection points.

Abstract: A method and system for drilling holes in a repaired composite structure. Four corner holes are selected from holes outside of a repaired area in the repaired composite structure. The four corner holes define a rectangle encompassing the repaired area with sides that each include a pair of corner holes with intermediate holes in between. A surface representation is generated based on a scan of the repaired composite structure that includes the rectangle. Side hole locations between a corresponding pair of corner holes are generated for each side of the rectangle. Grid vector lines are generated between corresponding pairs of side hole locations on opposite sides of the rectangle. The grid vector lines intersect each other at intersection points on the surface representation. Point coordinates are determined for intersection points that lie within the repaired area. A path is created for drilling holes at point coordinates for the intersection points.

Abstract: A method for implementing machining tasks for an object. The method identifies location coordinates for a plurality of holes. A task file contains the machining tasks. The robotic devices use the task files to perform the machining tasks. A minimum number of positioning stations is determined where a portion of the machining tasks will be performed by the robotic devices. An ordered sequence for performing the machining tasks is calculated and path a path with the near-minimum distance is determined. Robotic control files are created that cause the robotic devices to perform the machining tasks. The robotic control files are output to the robotic devices to perform the machining tasks to form the plurality of holes.

Abstract: A system for determining a camera pose relative to an object including a unique feature may include a monocular camera configured to produce an image of the object, and a processing unit in operative communication with the monocular camera. The processing unit may be configured to: identify the unique feature of the object in the image produced by the monocular camera, synthesize at least four points along a contour of the object in the image using the identified unique feature as a starting point, synthesize a same number of points as synthesized in the image along a contour of the object in a reference model, the reference model preprogrammed into a memory of the processing unit, correlate the points from the reference model to the image, and determine a pose of the monocular camera based on the correlated points.

Abstract: A system for determining a camera pose relative to an object including a unique feature may include a monocular camera configured to produce an image of the object, and a processing unit in operative communication with the monocular camera. The processing unit may be configured to: identify the unique feature of the object in the image produced by the monocular camera, synthesize at least four points along a contour of the object in the image using the identified unique feature as a starting point, synthesize a same number of points as synthesized in the image along a contour of the object in a reference model, the reference model preprogrammed into a memory of the processing unit, correlate the points from the reference model to the image, and determine a pose of the monocular camera based on the correlated points.