Patent Application
20250065515
The present invention relates to an attachment for a robotic arm that enables the robotic arm to be used as a reconfigurable fixture for vehicle manufacture and a method of using such an attachment as a reconfigurable fixture for vehicle manufacture.
Vehicle manufacture, and particularly, air vehicle manufacture traditionally requires complex manufacturing technologies commensurate with the complexity of the product being constructed. Conventional approaches to the location of individual elements of the vehicle usually rely on very expensively designed and manufactured “bespoke” fixtures. These fixtures have been meticulously constructed using very accurate metrology equipment. These fixtures attract a significant non-recurring and recurring cost penalty for their accuracy, can be very limited in their flexibility, and due to their bespoke nature tend to have a certain “shelf life” of use which then attracts further costs of disposal of the fixtures.
According to an aspect of the present invention, there is provided an interface node for enabling a robotic arm to be used as a reconfigurable fixture for vehicle manufacture. The interface node comprises an attachment element for attaching the interface node to the robotic arm. The interface node also comprises a first locating element, the first locating element comprising a flat surface wherein the flat surface is suitable for locating a first feature of a component of a vehicle wherein the first feature comprises a face of a component of a vehicle. The interface node further comprises a wall extending from and substantially around the flat surface, the wall connecting the flat surface to the attachment element wherein the wall defines a second locating element, the second locating element suitable for locating a second feature of a component of a vehicle.
In some examples the interface node further comprises a third locating element wherein the third locating element comprises one or more holes in the flat surface wherein each hole of the one or more holes is suitable for locating a third feature of a component of a vehicle wherein the third feature of a component of a vehicle comprises a point of a component of a vehicle. The one or more holes may comprise a hole at the centre of the flat surface. The one or more holes may be either screw holes or hollow cones. The one or more holes may comprise an array of screw holes and, optionally, the array of screw holes may comprise one or more of a 4 mm screw hole, a 5 mm screw hole, a 6 mm screw hole and a 7 mm screw hole.
In some examples, the second feature of a component of a vehicle is an edge of a component of a vehicle, the flat surface is circular, the wall is cylindrical, the second locating element is the cylindrical wall and a tangent to the cylindrical wall can be used to locate the edge of the component of a vehicle. In other examples the second feature of a component of a vehicle is a corner of a component of a vehicle, the flat surface is a rectangle, the wall is a rectangular prism, and the second locating element is a corner on the wall or a corner joining the flat surface to the wall wherein the corner on the wall or joining the flat surface and the wall can be used to locate the corner of the component of a vehicle.
In some examples, the attachment element is on an opposite side of the interface node to the flat surface. In other examples, the attachment element is connected to the wall of the interface node, and optionally, the interface node may further comprise a fourth locating element opposite the flat surface. The fourth locating element may comprise a cup suitable for locating a fourth feature of a component of a vehicle wherein the fourth feature comprises a cone.
In some examples, the attachment element comprises a clamp up location for clamping the interface node to the robotic arm, and a datum face for ensuring a known interface point between the robotic arm and the interface node.
According to another aspect of the present invention, there is provided a device for use as a reconfigurable support for vehicle manufacture. The device comprises a robotic arm wherein the robotic arm can be moved in 6 degrees of freedom, and an interface node such as the interface nodes described above wherein the interface node is connected to the robotic arm via the attachment element of the interface node.
According to a further aspect of the present invention, there is provided a method for locating a component of a vehicle relative to a vehicle build volume. The method comprises identifying a first feature of the component wherein the first feature of the component needs to be located to a desired position relative to the vehicle build volume. The method also comprises selecting a first locating element of an interface node connected to a robotic arm wherein the interface node comprises one or more locating elements wherein each locating element of the one or more locating elements is for locating a feature of a component of the vehicle and the first locating element is selected from the one or more locating elements to be suitable for locating the first feature of the component. The method further comprises determining a locating position for the first locating element based on the desired position of the first feature of the component. The method also comprises moving the interface node using the robotic arm to position the first locating element at the locating position. The method further comprises positioning the component relative to the vehicle build volume using the first locating element to locate the first feature of the component and hence the component with respect to the vehicle build volume.
In some examples, the one or more locating elements comprise at least one of a flat surface, a corner, a hole, a circular wall, and a cup and the first feature of the component comprises at least one of a face, a corner, a point, an edge, and a cone. Identifying a first locating element of the one or more locating elements on the interface node based on the first feature of the component may comprise: if the first feature of the component is a face selecting a flat surface of the interface node as the first locating element; if the first feature of the component is a corner selecting a corner of the interface node as the first locating element; if the first feature of the component is a point selecting a hole of the interface node as the first locating element; if the first feature of the component is an edge selecting a circular wall of the interface node as the first locating element; and if the first feature of the component is a cone selecting a cup of the interface node as the first locating element.
In some examples, the method may further comprise selecting the interface node from one of several interface nodes based on the first feature of the component wherein each of the several interface nodes comprise either different locating elements or differently sized locating elements.
In some examples, the method may comprise attaching the interface node to the robotic arm.
In some examples, positioning the component relative to the vehicle build volume further may comprise using the locating element to support the component in the desired position. The first feature may comprise a face, the first locating element may comprise a flat surface, and using the first locating element to support the component in the desired position may comprise supporting the face of the component on the flat surface of the interface node. The first feature may comprise a hole, the first locating element may comprise a screw hole, and using the first locating element to support the component in the desired position may comprise using a screw fitting to attach the component to the interface node via the hole and the screw hole. The first feature may comprise a cone, the first locating element may comprise a cup, and using the first locating element to support the component in the desired position comprises positioning the cone in the cup.
In some examples, the method may further comprise attaching the component to the vehicle build volume so that that component is supported by the vehicle build volume and moving the interface node away from the locating position using the robotic arm.
In some examples, the method may further comprise identifying a second feature of a second component that needs to be located to a second desired position relative to the vehicle build volume. The method may further comprise selecting a second locating element of the one or more locating elements on the interface node based on the second feature of the second component. The method may also comprise determining a second locating position for the second locating element based on the second desired position and moving the interface node using the robotic arm to position the second locating element at the second locating position. The method may also comprise positioning the second component relative to the vehicle build volume using the second locating element to locate the second feature of the second component and hence the second component with respect to the vehicle build volume. In some examples, the first and second locating element may be the same. However, in other examples the first and second locating element may be different.
In some examples, moving the interface node using the robotic arm to position the locating element at the locating position may comprise using the robotic arm to move the interface node in 6 degrees of freedom to drive the interface node such that the locating element is moved to the locating position.
Embodiments of the invention will now be described by way of example only with reference to the figures, in which:
This application relates to an attachment for a robotic arm that enables the robotic arm to be used as a third hand when positioning components for vehicle assembly, and in some examples air vehicle assembly. The attachment can also be known as a fixturing node, an interface node, an interface element, a fixturing element, a support element, or a support node.
In one example, an interface node for aiding in the building of a vehicle, such as an air vehicle, is provided. While the vehicle is being manufactured, it can exist in a partially built state known as a vehicle build volume or vehicle assembly. The interface node is designed to be connected or attached to a robotic arm or other suitable industrial robotics. To this end, the interface node comprises an attachment element for attaching the interface node to a robotic arm or other suitable form of industrial robotics. The attachment element can also be known as an attachment fixture, attachment fitting or attachment means. As well as comprising an attachment element, the interface node comprises one or more locating elements. The locating elements can also be known as locating features, locating means, or locating components. Each locating element from the one or more locating elements is suitable for locating, positioning, or picking up on a feature of a component for the vehicle. In other words, when the interface node is in a suitable position compared to the vehicle build volume and/or the partially complete vehicle, each locating element can be used to align/position a feature of a component of a vehicle to a desired position so that the feature of the component can be placed in a desired position compared to the vehicle build volume and/or partially complete vehicle. This means the component can be positioned correctly compared to the vehicle build volume. The desired position can be a position that ensures the component of the vehicle is positioned correctly compared to another part/component of the vehicle which forms part of the vehicle build volume or partially complete vehicle.
In another example, a method of using an interface node, such as the interface node described above is provided. The method comprises identifying a feature of a component of the vehicle that needs to be positioned with respect to a vehicle build volume in order to enable the component to be attached or otherwise form part of the vehicle build volume. In another example, the interface node could be used to support components during vehicle disassembly. The method comprises selecting a locating element from one or more locating elements on an interface node that is connected to a robotic arm. The locating element is chosen to be suitable for locating/aligning/positioning the identified feature of the component. For example, the form of locating element selected depends on the form of the identified feature such that the selected locating element and the identified feature correspond and/or are compatible. A locating element and an identified feature correspond when the locating element can be used to position/align that feature. The locating element can be chosen to be suitable to assist an end goal of positioning/locating/aligning the identified feature of the component. Examples of corresponding locating elements and features are described later. The method then comprises using the robotic arm to position the selected locating element at a position that is suitable for positioning the identified feature with respect to the vehicle build volume. This position can be determined based on a desired position of the feature of the component with respect to the vehicle build volume which in turn can be determined based on a desired position of the component with respect to the vehicle build volume. In some examples, the desired position may also be based on the size and shape of the component and/or the relative position of the feature of the component and the locating element on the interface node. Using the robotic arm can allow the interface node to be moved accurately in six degrees of freedom with respect to the build volume. The interface node can be driven by the robotic arm into the correct position. Once the interface node has been positioned, the selected locating element is then used to align/position/locate the identified feature of the component. In some examples this can involve using the locating element to support or otherwise hold the component. However, in addition or as an alternative, an additional support can be used to hold the component. The component can then be attached to the vehicle build volume and, once the component has been attached, the robotic arm can be used to move the interface node away from the component (after any disconnection of the component from the interface node where necessary). The interface node may then be reused to align/locate/position a second component with respect to the vehicle build volume using a second feature of the second component.
Attachment element 130 comprises a hole 130, which in some examples can be a screw hole. This hole 130 can be used to align/locate/pick up on a point of a component of a vehicle that needs to be positioned with respect to the vehicle build volume. Hole 130 may be a screw hole, plain hole, blind hole, through hole, threaded hole, counterbored hole, countersunk hole etc. Hole 130 may enable accurate location/positioning of a point of a component by aligning the point of the component with the hole 130. In some examples, this point can be a hole in the component of the vehicle. This may allow hole 130 to be used for support as well as alignment. In the example shown in
Attachment element 140 comprises the cylindrical wall 140. The use of a cylindrical wall 140 enables alignment of an edge of a component. As shown in
While the interface node 100 has been described as having a flat circular surface 120 and a cylindrical wall 140, the skilled person would understand that the flat surface and wall may have other geometries and may not be circular and cylindrical. For example, as shown in
Similarly, while the interface node 100 is described as having a central hole 130 that can comprise a screw hole, in some specific use cases the interface node 100 can instead comprise a cup such as a cone shaped cup that can be used to align a feature of a component of the vehicle comprising a cone to enable alignment of the cone compared to the vehicle build volume. In other examples the interface node 100 can comprise a protrusion and the feature of the component can comprise a matching cup in a shape other than a cone. In further examples, instead of a hole, a protrusion may be used as an alignment element in the interface node 100 to align with a corresponding/matching cup of the component. Alternatively, instead of a central hole 130, the flat surface 120 may comprise multiple holes such as an array of holes. These holes may comprise screw holes, basic circular holes, plain holes, blind holes, through holes, threaded holes, counterbored holes, countersunk holes or cups etc. of different sizes to enable the alignment of different sized hole, point, or protrusion features of a component. When an array of screw holes is used, the array of screw holes may comprise screw holes of at least one of 4 mm, 5 mm, 6 mm and 7 mm.
While an example attachment element has been described above, other attachment elements could also be used. For example, as shown in
In addition to the interface node 100, a further example described herein comprises a device for use as a reconfigurable support or as a reconfigurable alignment feature/fixture when building a vehicle, such as an air vehicle, or conducting vehicle, or air vehicle, manufacture. The device comprises an interface node 100 such as the interface node described above and a robotic arm or other suitable industrial robotics. The interface node 100 is connected to the robotic arm via the attachment element 110 of interface node 100. For example the attachment element 110 can be a zero-point clamp or other fixing used to connect the interface node 100 to a robotic arm via a robot end effector.
As shown in
In optional step 204, the interface node 900 is connected to a robotic arm or other industrial robotics using an attachment element such as attachment element 110. The interface node 900 comprises one or more locating elements such as locating elements 120, 130 and 140 described above. While in some examples this may form part of the method, the skilled person would understand that in other examples the interface node 900 may have been attached to the robotic arm or other industrial robotics before the start of the method.
The method 200 continues at step 206 where a first locating element of the one or more locating elements 120, 130, 140 on the interface node 900 is selected. The first locating element is selected based on the first feature of the component 980 such that the first locating element is suitable for locating/aligning/positioning the first feature of the component 980. For example, if the first feature of the component 980 is a face then a flat surface, such as flat surface 120 is chosen as a suitable first locating element. Similarly, if the first feature of the component is an edge, then a cylindrical or circular wall such as cylindrical wall 140 is chosen as the first locating element. In another example, if the first feature of the component is a point, for example a hole or other point, then hole 130 can be chosen as the first locating element. In all cases, the first locating element is chosen to be suitable for aligning/positioning/locating the first feature of the component and the first locating element and the first feature can be considered to correspond.
At step 208, the method 200 comprises determining a locating position of the first locating element based on the desired position of the feature of the component 980. As discussed above, the desired position reflects the position the first feature of the component 980 needs to be placed at in order to ensure the component is in a correct position with respect to the vehicle build volume 990. The desired position can be obtained from a plan of the vehicle, other details of the vehicle build or in any other suitable way. The locating position can then be determined based on the desired position. The locating position reflects a position at which the first locating element needs to be moved to/held or otherwise placed in to ensure that when the first locating element is used to locate/align/position the first feature of the component is in the desired position with respect to the vehicle build volume. In some examples, the desired position and locating position may be determined by a computer that calculates the desired position and locating position based on other components in the vehicle build volume and information about the final vehicle such as a plan of the vehicle. This increases the accuracy of the determined desired position and locating position and thus aids the use of the interface node to accurately position/locate components when building high precision vehicles.
The method then comprises, at step 210, moving the interface node 100 using the robotic arm or other industrial robotics so that the first locating element is in the locating position. This may be done automatically by a control system of the robotic arm or other industrial robotics to ensure the interface node 100 is positioned accurately. The robotic arm may move in six degrees of freedom (6DOF) and positioning the interface node may comprise moving the interface node in any of these 6DOF. The 6DOF may be movement along an X, Y and Z axis and pitch (movement between the X and Y axes), yaw (movement between the X and Z axes) and roll (movement between the Z and Y axes). The datum face can provide a known interface point to enable connection of the interface node 900 to a robotic arm via a robot end effector. The robotic arm may determine how to position/locate locating elements based on knowledge of a physical design of the interface node 900 and its key features and an imaginary robotic point by which the robot is driven around which is called the “robot tool centre point or TCP”.
Once the interface node 900 and the first locating element have been accurately positioned with respect to the vehicle build volume 990 or partially complete vehicle assembly/partially complete vehicle, the method 200 comprises at step 212, using the first locating element to locate/position/align the first feature of the component 980. This enables the first feature of the itself to be component 980, and hence the component 980 positioned/aligned/located with respect to the vehicle build volume 990. The use of the first locating element depends on the form of the first locating element and the first feature of the component 980.
For example, as shown in
When the first feature of the component is a point, such as a hole, then the point can be aligned to the hole 130 locating element. This can involve aligning the point with the hole 130 or the centre of the hole 130. When the point on the component is itself a hole and locating element hole 130 is a screw hole, this can involve using a screw to fix the component in place and hence support the component. In other examples, the hole 130 of the locating element and the hole of the component can be affixed using other means. In addition, a point on the component can be aligned to a hole 130 and the component can be supported on the flat surface 920 of the interface node 900 during the alignment. Thus, in the above examples, the interface node 100 can be used to both align/position and support the component. However, in other examples, while the point can be aligned to the hole alignment element 130, the hole alignment element 130 acts as an alignment and further support may be needed to hold the component in position.
When the first feature of the component is an edge, the edge can be aligned at a tangent to the cylindrical wall alignment component 140 enabling an accurate point alignment as described with respect to
Once the component has been aligned to the vehicle build volume using the first feature of the component and the first alignment element of the interface node, the component can be fixed in position with respect to the vehicle build volume e.g. using a screw, rivet, bolt etc. The component can then be fully supported by the vehicle build volume. If the first feature of the component has been supported by the first locating element, any connections or attachments between the component and the interface node can then be undone. The robotic arm or other industrial robotics can then be used to move the interface node away from the locating position and hence the vehicle build volume leaving the component in place. The above method can then be repeated with a second feature on a second component so that a second component can be positioned with respect to the vehicle build volume.
In some examples, the above method 200 may further comprise a step of selecting an interface node 100 from several interface nodes. In this case, each interface node 100 of the several interface nodes may comprise differently sized locating elements. For example, the flat surface 120 on each interface node 100 may be a different size to enable support of differently sized faces of components of the vehicle. In another example, the hole 130 on each interface node 100 may be a different size to enable the alignment of differently sized holes or points on components. In addition or as an alternative, each interface node 100 of the several interface nodes may comprise different locating elements. For example, one interface node may comprise a circular flat surface 120 and a cylindrical wall 140 while another interface node may comprise a rectangular (including square) flat surface and a rectangular prism (including a square prism) wall. An interface node can then be chosen based on whether the user wishes to align an edge feature of a component of a vehicle or a corner feature of a component of a vehicle.
In addition, while the method above has been described with respect to features of a component that comprise faces, points and edges, the skilled person would understand that depending on the interface component other features of a component can be aligned. For example, if the first feature of the component is a corner then a corner of the interface node 100 can be selected as the first locating element. This corner may be on a rectangular (including square) prism of a wall of the interface node 100 or be between a rectangular flat surface (including square) and a rectangular prism (including square prism) wall of the interface node. To use the corner as a locating element, the corner that is the first feature of the component can be aligned with the corner that is the first locating element of the interface node 100. Similarly, if the first feature of the component is a cone, then a corresponding/matching cup of the interface node 100 can be selected as the first locating element. The cup may be formed in the flat surface 120 or may be in a surface opposite flat surfaced 120. Aligning/locating the cone of the component with the cup of the interface node 100 may comprise positioning the cone of the component in the cup of the interface node 100.
The use of an interface node 100 and the method 200 described above is highly versatile. Given the interface node 100 comprises flexible locating elements such as flat surfaces 120, holes 130 and circular/cylindrical walls 140, the locating elements can be used to align general features of a component such as faces, points and edges. Thus, there is no need to design and use specific jigs/alignment tools for each component and/or each feature that needs to be aligned or even for each type of feature that needs to be aligned. The interface node 100 can be used for multiple vehicles and/or types of vehicles removing the need for a specific jig or alignment tool per vehicle. In addition, in many examples, the interface node 100 comprises multiple different locating elements. Thus, the same interface node can therefore be used to align different features of components. In addition, since the interface node 100 is designed to connect to a robotic arm or other industrial robotics via a robot end effector, the interface node 100 can be accurately repositioned. The interface node 100 and the method 200 can therefore be used to act as a support for multiple different components at different times based on different features of the components. Unlike conventional bespoke fittings and jigs, this allows easy adaption of the supports/alignment fixtures for positioning components with respect to a vehicle build volume. This allows easy adaptation to redesign of the vehicle and also enables the addition of bespoke features to a vehicle without the requirement to make bespoke jigs/fixtures for building the vehicle.
The attachment/interface node of the above examples aids in being able to accurately locate and maintain that accuracy of particular unsupported air vehicle components during the vehicle assembly process. In one example, industrial robotics is used, and a particularly designed interface node is attached to the industrial robotics that would allow technology engineers the ability to flexibly interface with typical features of air vehicle products. These features typically are holes, faces and points on surfaces (tangential interfacing) of components. The example involves accurately “driving” the node digitally to desired positions in the air vehicle build volume such that the once unsupported component can be digitally fixed in position via the accurate location of the interface node prior to the final assembly of that component to its adjacent components and so becoming “self-supporting”. The interface node is infinitely programmable, product agnostic in nature and as such allows for late vehicle design incorporation without the traditional costly redesign of the aforementioned “bespoke” fixturing solutions. The all-encompassing principle of this application is the transition to a more digitally secured build methodology for next generation air vehicles, but this approach could be adopted across a myriad of industrial sectors.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21275189.5 | Dec 2021 | EP | regional |
| 2118348.8 | Dec 2021 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/GB2022/053120 | 12/7/2022 | WO |
