Real-time feedback control for performing tooling operations in assembly processes

Patent metadata

Field	Value
Publication number	US-10162317-B2
Application number	US-201313929138-A
Country	US
Kind code	B2
Filing date	Jun 27, 2013
Priority date	Jun 27, 2013
Publication date	Dec 25, 2018
Grant date	Dec 25, 2018

Abstract

A method and apparatus for controlling a tooling operation to be performed by a tooling system in an assembly process. A current set of parameter values for a set of parameters for the tooling system are modified iteratively, until the current set of parameter values are determined to result in the tooling operation producing an output that meets a set of criteria, to form a final set of parameter values. The tooling operation is performed with the tooling system using the final set of parameter values. A determination is made as to whether the output of the tooling operation meets the set of criteria based on sensor data about the output. A new set of parameter values are identified as the current set of parameter values to be evaluated in response to a determination that the output of the tooling operation does not meet the set of criteria.

First claim

What is claimed is:

1. A method for performing a riveting operation by a riveting system, the method comprising:
modifying, iteratively by a computer system, a current set of parameter values for a set of parameters for the riveting system, until the current set of parameter values predict the riveting operation producing a riveted structure that meets a set of criteria, to form a final set of parameter values, wherein the riveting system comprises a first robotic arm having an anvil or die for applying a first force to deform a first end of a member inserted between a first plate and a second plate, a second robotic arm having a die for applying a second force to deform a second end of the member, and a position tracker configured to track a position of the riveting system, wherein the position tracker sends position data to a controller;
performing the riveting operation with the riveting system using the final set of parameter values to produce the riveted structure, wherein the riveted structure comprises the first plate, the second plate, and a rivet formed by deforming the first end of the member into a first end shape and the second end of the member into a second end shape, wherein the first end is cylindrical having a first diameter and the second end is hemispherical having a height and a second diameter adjacent the second plate;
determining, by the computer system, whether the riveted structure of the riveting operation meets the set of criteria based on sensor data about the riveted structure of the riveting operation, wherein when a decision is made that the riveted structure of the riveting operation does not meet the set of criteria, the current set of parameter values for the set of parameters for the riveting system are recalculated while concurrently performing a number of tooling operations, wherein recalculating is defined as identifying a new set of parameters that allow a tooling operation to be performed according to the set of criteria that reduces an amount of error associated with the tooling operation, wherein the number of tooling operations includes the riveting operation, a drilling operation, a fastening operation, a nailing operation, and a rotating operation; and
identifying, by the computer system, a new set of parameter values as the current set of parameter values to be evaluated in response to a determination that the riveted structure of the riveting operation does not meet the set of criteria.

2. The method of claim 1 further comprising:
repeating modifying, iteratively by the computer system, the current set of parameter values to form the final set of parameter values after identifying the new set of parameter values as the current set of parameter values to be evaluated.

3. The method of claim 1 , wherein modifying, iteratively, the current set of parameter values to form the final set of parameter values comprises:
forming, by the computer system, a number of models of the riveted structure that would be produced by the riveting operation based on the current set of parameter values;
determining, by the computer system, whether the riveted structure that would be produced by the riveting operation meets the set of criteria; and
identifying, by the computer system, the new set of parameter values to be evaluated as the current set of parameter values in response to the determination that the riveted structure that would be produced by the riveting operation does not meet the set of criteria.

4. The method of claim 3 , wherein forming the number of models of the riveted structure that would be produced by the riveting operation based on the current set of parameter values comprises:
forming, by the computer system, the number of models of the riveted structure that would be produced by the riveting operation based on the current set of parameter values using finite-element assisted modeling.

5. The method of claim 1 further comprising:
generating the sensor data about a set of properties of the riveted structure of the riveting operation using a laser sensor device, wherein the set of properties includes at least one of the first end shape and the second end shape.

6. The method of claim 1 further comprising:
generating the sensor data about a set of properties of the riveted structure of the riveting operation using a backscatter x-ray sensor device, wherein the set of properties includes interface properties of an interference fit formed by the interface between a rivet in the riveted structure produced by the riveting operation and a set of plates fastened together by the riveting operation.

7. The method of claim 1 further comprising:
identifying, by the computer system, an initial set of parameter values for the set of parameters for the riveting system as the current set of parameter values to be evaluated based on the riveting operation to be performed, wherein the riveting operation is an operation in an assembly process.

8. The method of claim 1 , wherein determining whether the riveted structure that would be produced by the riveting operation meets the set of criteria comprises:
running, by the computer system, at least one of a number of tests and a number of simulations based on a number of models to form test data; and
determining, by the computer system, whether the riveted structure that would be produced by the riveting operation meets the set of criteria based on the test data, wherein the set of criteria includes specifications about a set of properties of the riveted structure, wherein the set of properties includes:
the first end shape of the rivet in the riveted structure produced by the riveting operation;
the second end shape of the rivet in the riveted structure produced by the riveting operation; and
interface properties of an interference fit formed by an interface between the rivet in the riveted structure produced by the riveting operation and a set of plates fastened together by the riveting operation;

wherein the set of plates comprises the first plate and the second plate.

9. An apparatus comprising:
a riveting system comprising a first robotic arm having an anvil or die for applying a first force to deform a first end of a member inserted between a first plate and a second plate, a second robotic arm having a die for applying a second force to deform a second end of the member, and a position tracker configured to track a position of the riveting system, wherein the position tracker sends position data to a controller;
a riveted structure formed by the riveting system, wherein the riveted structure comprises the first plate, the second plate, and a rivet formed by deforming the first end of the member into a first end shape and the second end of the member into a second end shape, wherein the first end is cylindrical having a first diameter and the second end is hemispherical having a height and a second diameter adjacent the second plate;
a modeler configured to modify, iteratively, a current set of parameter values for a set of parameters for the riveting system, until the current set of parameter values predict a riveting operation producing the riveted structure that meets a set of criteria, to form a final set of parameter values;
a quality checker configured to determine whether the riveted structure of the riveting operation meets the set of criteria based on sensor data about the riveted structure of the riveting operation, wherein when a decision is made that the riveted structure of the riveting operation does not meet the set of criteria, the current set of parameter values for the set of parameters for the riveting system can be recalculated while concurrently performing a number of tooling operations, wherein recalculating

Assignees

• Boeing Co

Inventors

• Toh Chin H

Classifications

• B21J15/285

  for controlling the rivet upset cycle · CPC title

• G05B19/41885

  characterised by modeling, simulation of the manufacturing system · CPC title

• B21J15/02

  Riveting procedures · CPC title

• G05B13/042

  in which a parameter or coefficient is automatically adjusted to optimise the performance · CPC title

• G05B2219/32182

  If state of tool, product deviates from standard, adjust system, feedback · CPC title