Abstract: One variation of a method includes: accessing a maximum deflection distance of a workpiece; defining a first workpiece region characterized by a first compliance range; defining a second workpiece region characterized by a second compliance range greater than the first compliance range; assigning a nominal target force to the workpiece; navigating a sanding head across the first workpiece region during a processing cycle; driving the sanding head below a virtual unloaded surface of the workpiece stored in the virtual model to maintain forces, of the sanding head on the first workpiece region, approximating the nominal target force; calculating a maximum offset between the positions of the sanding head in the first workpiece region and the virtual unloaded surface; and, in response to the first maximum offset approaching the maximum deflection distance, assigning a lower target force to the second workpiece region of the workpiece.

Abstract: A method includes: accessing a toolpath and processing parameters—including a target force and feed rate—assigned to a region of a workpiece; and accessing a wear model representing abrasive degradation of a sanding pad arranged on a sanding head. The method also includes, during a processing cycle: accessing force values output by a force sensor coupled to the sanding head; navigating the sanding head across the workpiece region according to the toolpath and, based on the force values deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece region proximal the target force; accessing contact characteristics representing contact between the sanding pad and the workpiece; estimating abrasive degradation of the sanding pad based on the wear model and the sequence of contact characteristics; and modifying the set of processing parameters based on the abrasive degradation.

Abstract: A method includes: compiling images, captured by an end effector traversing a scan path over a workpiece, into a virtual model of the workpiece; generating a toolpath based on a geometry of the workpiece represented in the virtual model; and assigning a target force to the workpiece. The method also includes, during a processing cycle: navigating a sanding head, arranged on the end effector, across the workpiece according to the toolpath; based on force values output by a force sensor coupled to the sanding head, deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece proximal the target force; and tracking a sequence of positions of a reference point on the sanding head, traversing the workpiece, in contact with the workpiece. The method also includes transforming the virtual model into alignment with the sequence of positions of the reference point.

Abstract: A system includes: a pad removal assembly; a replacement pad reservoir; an inspection unit; and a controller. The pad removal assembly includes: a separating element arranged proximal a slot; and a guide surface opposite the separating element. The replacement pad reservoir: arranged adjacent the separating element and housing sanding pads configured to couple the sanding head; and including an aperture in alignment with the guide surface. The inspection unit includes an optical sensor defining a field of view directed toward an imaging plane. The controller configured to: access an image recorded by the optical sensor depicting an abrasive area of a sanding pad arranged on a sanding head; extract features from the image; interpret an abrasive degradation for the abrasive area in the image based on the features; and in response to the abrasive degradation exceeding a threshold degradation, triggering a tool change cycle.

Abstract: A method includes: accessing a toolpath and processing parameters—including a target force and feed rate—assigned to a region of a workpiece; and accessing a wear model representing abrasive degradation of a sanding pad arranged on a sanding head. The method also includes, during a processing cycle: accessing force values output by a force sensor 199 coupled to the sanding head; navigating the sanding head across the workpiece region according to the toolpath and, based on the force values deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece region proximal the target force; accessing contact characteristics representing contact between the sanding pad and the workpiece; estimating abrasive degradation of the sanding pad based on the wear model and the sequence of contact characteristics; and modifying the set of processing parameters based on the abrasive degradation.

Abstract: One variation of a method for autonomously scanning and processing a part includes: accessing a part model representing a part positioned in a work zone adjacent a robotic system; retrieving a sanding head translation speed; retrieving a toolpath for execution on the part defining positions, orientations, and target forces applied by the sanding head to the part. The method includes traversing the sanding head along the toolpath, at the sanding head translation speed; reading a sequence of applied forces from a force sensor coupled to the sanding head at positions along the toolpath; and deviating from the toolpath to maintain the set of applied forces within a threshold difference of a sequence of target forces along the toolpath. In one variation of the method, the robotic system executes a toolpath at a duration less than target duration by selectively varying target force and sanding head translation speed across the part.

Abstract: A method includes, traversing a laser line scanning sensor over a workpiece to generate a series of scan data according to a first set of scan parameters; assembling the series of scan data into a virtual model; detecting a first hole, defining absence of scan data, in a first region of the virtual model; responsive to the first hole defining a dimension less than a threshold dimension, assigning the first set of scan parameters to the first region; detecting a second hole, in a second region of the virtual model; responsive to the second hole defining a dimension greater than the threshold dimension, defining a second set of scan parameters associated with an increased resolution and assigning the second set of scan parameters to the second workpiece region; and compiling the first and second set of scan parameters into a scan protocol defining a minimum scan cycle duration.

Abstract: A method for media blasting a workpiece includes, during a scan cycle: accessing a first set of images captured by an optical sensor traversing a scan path over the workpiece; compiling the first set of images into a virtual model of the workpiece; accessing a first set of blast parameters; generating a first tool path for a first workpiece region of the workpiece based on a geometry of the workpiece represented in the virtual model and the first set of blast parameters. The method further includes, during a processing cycle: via the set of actuators, navigating the blast nozzle over the first workpiece region according to the first tool path; and projecting blasting media toward the workpiece according to the first set of blast parameters.

Abstract: A method for autonomously grinding a workpiece includes: accessing a virtual model defining a geometry of the workpiece; identifying a grinding region on the workpiece; and projecting a target grinding profile onto the grinding region on the workpiece. The method also includes: based a geometry of the workpiece and the target grinding profile, generating a tool path for removal of material from the grinding region to the target grinding profile; and assigning a target force to the target region. The method also includes, during a processing cycle: accessing a sequence of force values output by a force sensor coupled to a grinding head; navigating the grinding head across the grinding region according to the tool path; and, based on the sequence of force values, deviating the grinding head from the tool path to maintain forces of the grinding head on the grinding region proximal the target force.

Abstract: A method includes: accessing a coating thickness range for workpiece coating; triggering an optical sensor to capture scan data representing the workpiece; triggering a depth sensor to capture a first depth value; assembling the scan data into a first virtual model representing the workpiece; defining first spray parameters corresponding to a minimum coating thickness; defining a first toolpath; driving a coating applicator along the first toolpath to spray the coating onto the workpiece; triggering the depth sensor to capture a second depth value; calculating a first coating thickness based on the first depth value and the second depth value; in response to the first coating thickness falling below the target minimum coating thickness defining a second set of spray parameters and a second toolpath; and driving the coating applicator along the second toolpath to spray the coating onto the workpiece according to the second set of spray parameters.

Abstract: A method includes, traversing a laser line scanning sensor over a workpiece to generate a series of scan data according to a first set of scan parameters; assembling the series of scan data into a virtual model; detecting a first hole, defining absence of scan data, in a first region of the virtual model; responsive to the first hole defining a dimension less than a threshold dimension, assigning the first set of scan parameters to the first region; detecting a second hole, in a second region of the virtual model; responsive to the second hole defining a dimension greater than the threshold dimension, defining a second set of scan parameters associated with an increased resolution and assigning the second set of scan parameters to the second workpiece region; and compiling the first and second set of scan parameters into a scan protocol defining a minimum scan cycle duration.

Abstract: A method includes: accessing a virtual model defining a geometry of a workpiece; navigating an optical sensor about the workpiece; accessing an image of the workpiece; detecting a marker, on the workpiece, depicted in the image; defining a first workpiece region of the workpiece bounded by the marker; defining a toolpath within the first workpiece region based on a geometry of the first workpiece region represented in the virtual model; assigning a first target force to the first toolpath; and during a processing cycle accessing a first sequence of force values output by a force sensor coupled to the sanding head, navigating the sanding head across the first workpiece region according to the first toolpath, and based on the first sequence of force values, deviating the sanding head from the first toolpath to maintain forces of the sanding head on the workpiece proximal the first target force.

Abstract: A method includes: accessing a coating thickness range for workpiece coating; triggering an optical sensor to capture scan data representing the workpiece; triggering a depth sensor to capture a first depth value; assembling the scan data into a first virtual model representing the workpiece; defining first spray parameters corresponding to a minimum coating thickness; defining a first toolpath; driving a coating applicator along the first toolpath to spray the coating onto the workpiece; triggering the depth sensor to capture a second depth value; calculating a first coating thickness based on the first depth value and the second depth value; in response to the first coating thickness falling below the target minimum coating thickness defining a second set of spray parameters and a second toolpath; and driving the coating applicator along the second toolpath to spray the coating onto the workpiece according to the second set of spray parameters.

Abstract: One variation of a method for autonomously scanning and processing a part includes: collecting a set of images depicting a part positioned within a work zone adjacent a robotic system; assembling the set of images into a part model representing the part. The method includes segmenting areas of the part model—delineated by local radii of curvature, edges, or color boundaries—into target zones for processing by the robotic system and exclusion zones avoided by the robotic system. The method includes: projecting a set of keypoints onto the target zone of part model defining positions, orientations, and target forces of a sanding head applied at locations on the part model; assembling the set of keypoints into a toolpath and projecting the toolpath onto the target zone of the part model; and transmitting the toolpath to a robotic system to execute the toolpath on the part within the work zone.

Abstract: A method includes: accessing a coating thickness range for workpiece coating; triggering an optical sensor to capture scan data representing the workpiece; triggering a depth sensor to capture a first depth value; assembling the scan data into a first virtual model representing the workpiece; defining first spray parameters corresponding to a minimum coating thickness; defining a first toolpath; driving a coating applicator along the first toolpath to spray the coating onto the workpiece; triggering the depth sensor to capture a second depth value; calculating a first coating thickness based on the first depth value and the second depth value; in response to the first coating thickness falling below the target minimum coating thickness defining a second set of spray parameters and a second toolpath; and driving the coating applicator along the second toolpath to spray the coating onto the workpiece according to the second set of spray parameters.

Abstract: A method includes, traversing a laser line scanning sensor over a workpiece to generate a series of scan data according to a first set of scan parameters; assembling the series of scan data into a virtual model; detecting a first hole, defining absence of scan data, in a first region of the virtual model; responsive to the first hole defining a dimension less than a threshold dimension, assigning the first set of scan parameters to the first region; detecting a second hole, in a second region of the virtual model; responsive to the second hole defining a dimension greater than the threshold dimension, defining a second set of scan parameters associated with an increased resolution and assigning the second set of scan parameters to the second workpiece region; and compiling the first and second set of scan parameters into a scan protocol defining a minimum scan cycle duration.

Abstract: A method includes: accessing a virtual model defining a geometry of a workpiece; navigating an optical sensor about the workpiece; accessing an image of the workpiece; detecting a marker, on the workpiece, depicted in the image; defining a first workpiece region of the workpiece bounded by the marker; defining a toolpath within the first workpiece region based on a geometry of the first workpiece region represented in the virtual model; assigning a first target force to the first toolpath; and during a processing cycle accessing a first sequence of force values output by a force sensor coupled to the sanding head, navigating the sanding head across the first workpiece region according to the first toolpath, and based on the first sequence of force values, deviating the sanding head from the first toolpath to maintain forces of the sanding head on the workpiece proximal the first target force.

Abstract: A method includes, during a processing cycle: navigating the sanding head across a region of a workpiece according to a toolpath; and, based on a sequence of force values output by a force sensor coupled to the sanding head, deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece region proximal a target force. The method also includes: detecting a sequence of positions of the sanding head traversing the workpiece region; interpreting a surface contour in the workpiece region based on the sequence of positions; detecting a difference between the surface contour and a corresponding target surface defined in a target model of the workpiece; generating a second toolpath for the workpiece region based on the difference; and, during a second processing cycle, navigating the sanding head across the workpiece region according to the second toolpath to reduce the difference.

Abstract: A method includes: compiling lower-resolution images, captured during a global scan cycle executed over a workpiece, into a virtual model; defining a nominal toolpath and a nominal target force for the workpiece based on a the virtual model; detecting a defect indicator on the workpiece based on the lower-resolution images; accessing a higher-resolution image captured during a local scan cycle over the defect indicator; characterizing the defect indicator as a defect reparable via material removal based on the higher-resolution image; defining a repair toolpath for the defect based on the virtual model; navigating a sanding head over the workpiece according to the repair toolpath to repair the defect; and, during a processing cycle: navigating the sanding head across the workpiece according to the nominal toolpath and deviating the sanding head from the nominal toolpath to maintain forces of the sanding head on the workpiece proximal the nominal target force.

Abstract: A method includes: accessing a virtual model defining a geometry of a workpiece; navigating an optical sensor about the workpiece; accessing an image of the workpiece; detecting a marker, on the workpiece, depicted in the image; defining a first workpiece region of the workpiece bounded by the marker; defining a toolpath within the first workpiece region based on a geometry of the first workpiece region represented in the virtual model; assigning a first target force to the first toolpath; and during a processing cycle accessing a first sequence of force values output by a force sensor coupled to the sanding head, navigating the sanding head across the first workpiece region according to the first toolpath, and based on the first sequence of force values, deviating the sanding head from the first toolpath to maintain forces of the sanding head on the workpiece proximal the first target force.