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 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 flexible track drilling machine employs a pair of rails that are flexible in one direction to conform to a non-flat workpiece surface and are substantially stiff in a direction parallel to the workpiece surface. The rails are attached to the workpiece by vacuum cups spaced along each rail. An X-axis carriage is slidably mounted on the rails by rollers mounted on flexible spring plates affixed to the carriage. A drill or other device to be positioned is mounted on a Y-axis carriage that is slidably connected to the X-axis carriage. The three-dimensional surface of the workpiece is mathematically transformed into a two-dimensional flat pattern, and the positioning of the carriages is controlled based on the flat pattern.

Abstract: Methods and apparatus for track members having a neutral axis rack are disclosed. In one embodiment, an apparatus for supporting a manufacturing tool relative to a workpiece includes a track assembly adapted to be attached to the workpiece and including at least one rail, the rail having a longitudinally-extending neutral axis and a rack extending along a pitch line that at least approximately coincides with the longitudinally-extending neutral axis. In alternate embodiments, the rack includes a plurality of wedge-shaped apertures or a plurality of conically-shaped apertures.

Abstract: Methods and apparatus for counterbalanced manufacturing operations are disclosed. In one embodiment, an apparatus for supporting a tool relative to a surface of a workpiece includes a base adapted to be attached to the workpiece, a tool support coupled to the base, and a biasing device coupled to both the base and the tool support. The tool support is moveable relative to the base along a translation axis, and the biasing device is biasable along a biasing axis that is at least partially along the translation axis. The biasing device is adapted to at least partially counterbalance a force (e.g. a gravitational force) exerted on the tool support along the translation axis.

Abstract: A power feed apparatus for applying a thrust force to an output shaft of a motor driven tool to drive the output shaft linearly towards and away from a workpiece without applying off-axis forces to the output shaft that would cause it to move out of perfect perpendicular alignment to the outer surface of the workpiece. The apparatus includes a first tubular member which is fixedly secured to a jig or other like mounting structure associated with the workpiece. A second tubular member is disposed for sliding linear movement along the first tubular member. Spaced apart annular fluid chambers are formed within the apparatus along with associated fluid ports for allowing a pressurized fluid to be used to both extend and retract the output shaft of the tool. The tool itself is supported on the second tubular member and thus moves linearly along with the second tubular member.

Abstract: A power feed apparatus for applying a thrust force to an output shaft of a motor driven tool to drive the output shaft linearly towards and away from a workpiece without applying off-axis forces to the output shaft that would cause it to move out of perfect perpendicular alignment to the outer surface of the workpiece. The apparatus includes a first tubular member which is fixedly secured to a jig or other like mounting structure associated with the workpiece. A second tubular member is disposed for sliding linear movement along the first tubular member. Spaced apart annular fluid chambers are formed within the apparatus along with associated fluid ports for allowing a pressurized fluid to be used to both extend and retract the output shaft of the tool. The tool itself is supported on the second tubular member and thus moves linearly along with the second tubular member.

Abstract: A flexible track drilling machine employs a pair of rails that are flexible in one direction to conform to a non-flat workpiece surface and are substantially stiff in a direction parallel to the workpiece surface. The rails are attached to the workpiece by vacuum cups spaced along each rail. An X-axis carriage is slidably mounted on the rails by rollers mounted on flexible spring plates affixed to the carriage. A drill or other device to be positioned is mounted on a Y-axis carriage that is slidably connected to the X-axis carriage. The three-dimensional surface of the workpiece is mathematically transformed into a two-dimensional flat pattern, and the positioning of the carriages is controlled based on the flat pattern.

Abstract: A tack fastener temporarily holds two or more parts together. An elongate tubular body of the tack fastener includes a longitudinal center cavity formed therein along a longitudinal center axis. A threaded hub is provided at a first end of the body and a plurality of tangs at a second end. Each of the tangs includes an enlarged tip having an inner shoulder that lies orthogonal to the longitudinal center axis. Each of the tangs has an outer surface which tapers inwardly toward the longitudinal axis in a direction toward the tip. A compression nut is mounted on the threaded hub. A stem is slidably mounted in the longitudinal center cavity. The stem includes a cone-shaped spreader with a distal end and having a contact surface with a gradually enlarging diameter in a direction toward the distal end. The spreader is movable between a position out of alignment with and a position in alignment with the enlarged tips.

Abstract: A marine drive which mounts through a hole in the bottom surface of a boat utilizes a driveshaft housing assembly, an engine mounted to the driveshaft assembly and a lower propeller drive unit mounted to the driveshaft housing assembly. The driveshaft housing assembly which mounts the drive within the hole in the boat includes a driveshaft housing, a steering assembly constructed to rotate about a generally vertical axis within said driveshaft housing assembly to provide steering, a trimming assembly connected to the steering assembly to pivotably swing the lower propeller drive unit to provide trimming/tilting, a driveshaft and an exhaust passageway therethrough.